Anda di halaman 1dari 358

Original Instructions

Operator’s manual
qi441
serial number 1884BG13240
WARNING
IGNORING INSTRUCTIONS HAZARD

To avoid death or injury you MUST read, understand and follow the
Manual before installing, inspecting, operating, servicing, testing,
cleaning, transporting, storing, dismantling or disposing of the
product or a part or accessory of the product.
qi441
© Copyright Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
All rights reserved. No parts of this document may be reproduced or
copied in any form or by any means without written permission from Sandvik Mining and
Construction Mobile Crushers and Screens Ltd.
All data and information in this manual may be changed without further notice.
Reservations for misprints.

For further information, please contact:

Sandvik Mining and Construction Mobile Crushers and Screens Ltd.


Tullyvannon, Ballygawley
Co. Tyrone
N. Ireland
BT70 2HW
Telephone: (+44) 028 855 67799
Facsimile: (+44) 028 855 67007
e-mail: mobilecs.smc@sandvik.com
Contents
1.0 Safety Section - Introduction 7
1.1 The purpose of these instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2 Identification of the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.1 Product type and serial number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
1.2.2 Product manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.3 Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
1.2.4 How to identify the right manual for the product. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.2.5 Validity of the manuals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3 Copyright notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.4 Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

2.0 Safety Section - Safety and Environmental Instructions 13


2.1 Safety labels and signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.1 Signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.2 General hazard symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1.3 Symbols for mandatory actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1.4 Symbols for prohibited actions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.5 Hazard symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.1.6 Labels on the product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.1.7 Visual and audible signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2 User obligations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
2.2.1 Managing work related hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
2.2.2 Scheduled safety inspections and preventive maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 26
2.2.3 Personal protective equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
2.3 Product limitations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.3 Prohibited use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.5 Maximum inclination angles during tramming and parking . . . . . . . . . . . . . . . . . . . . . . . . . . 28
2.3.6 Maximum inclination angles during operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.3.7 Modifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
2.4 Hazard zones . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.4.1 Exclusion zone for QI441. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
2.5 Safeguarding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5.1 Guards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
2.5.2 Protective Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.6 Complementary protective measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.1 Use of Emergency stop function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
2.6.2 Emergency exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.3 Safe access to machinery and three point support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
2.6.4 Isolation and energy dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
2.6.5 Fire risk control measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
2.7 Protection against emission hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7.1 Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
2.7.2 Vibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.7.3 Dust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
2.8 Emergency procedures and methods for unblocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
2.9 Safety considerations for maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
2.10 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.10.1 Decommissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.10.2 Dismantling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
2.10.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
2.11 Potential product related hazards identified by the user . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
2.12 Incident reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

3.0 Transport &Technical Data 53


3.1 Transport. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

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3.1.1 Special Considerations For Transport Of The QI441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.1.2 Machine Preparation for Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
3.1.3 Folding the main conveyor and Positioning into Transport Position . . . . . . . . . . . . . . . . . . . 55
3.1.4 Folding the Natural Fines Conveyor and removing the belt troughs . . . . . . . . . . . . . . . . . . . 56
3.1.5 Folding the hopper sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
3.2 Additional Machine Preparation for Transport for Hanging Screen . . . . . . . . . . . . . . . . . . . Options60
3.2.1 Raising the Recirculation Jack Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.2 Preparing the Midsize Transfer Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
3.2.3 Preparing the Primary Screen Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
3.2.4 Preparing the secondary screen box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
3.2.5 Preparing the Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.6 Preparing the Stock pile Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
3.2.7 Positioning the Recirculation Conveyor into transport position . . . . . . . . . . . . . . . . . . . . . . . 65
3.2.8 Preparing ladder 1 and ladder 2 for transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
3.2.9 Store the Loose Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
3.2.10 Tracking the machine onto and off the transport vehicle . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
3.2.11 QI441 Hanging Screen Transport and Working Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 71
3.2.12 QI441 Transport And Working Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
3.3 Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4 Technical Data and General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.1 Feed Hopper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.2 Primary Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.3 Pre screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.4 Impactor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.5 Main Conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
3.4.6 Natural Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.7 Power Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.8 Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.9 Hanging Screen Option Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.10 Recirculating Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.11 Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.12 Stockpile Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
3.4.13 Transfer Conveyor (Oversize and Midsize) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.14 Underpan feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.4.15 Double Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.5 General Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
3.6 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.1 Hopper extensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.2 Hopper Hardox liner plates back and sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.3 High impact Sandvik wear rubber back and sides. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.4 Central auto lube (crusher only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.5 Central auto lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.6 Remote Diesel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.7 Water pump (Hyd) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.8 Artic Packages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.9 Tropical / High ambient package (may not be required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.10 Wheeled Dolly (Open circuit only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.11 Conveyor pull cords . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.12 Grizzly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.13 Pre screen top deck punch plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.14 Pre screen top deck mesh (ashalt / secondary applications) . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.15 Pre screen open bottom rubber to feed natural fines conveyor (high fine / sticky applications)
80
3.6.16 No overband magnet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
3.6.17 No natural fines conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

4.0 Product Overview 81


4.1 Product Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

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4.2 Major Components QI441. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
4.2.1 Hanging Screen [ QI441 HS ] Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
4.3 Identification and Operation of the QI441 Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3.1 Main Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
4.3.2 Hydraulic Control Banks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
4.3.3 Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted . . . . . . . . . . . . . . 87
4.3.4 Flow Control Valves with Hanging Screen [ QI441 HS ] Option Fitted . . . . . . . . . . . . . . . . . 88
4.3.5 Radio Remote Control Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
4.3.6 Umbilical Remote Control Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

5.0 Commissioning and Shut Down 91


5.1 Commissioning & Shutdown Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
5.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2.1 Preparation for Machine STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
5.2.2 Engine Start-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
5.2.3 Setting Language of Control Panel Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
5.2.4 Setting the date/time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
5.2.5 Sequence For Tracking Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
5.3 Initial Setup and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.1 Remove the Loose Items. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
5.3.2 Set Up ladder 1 and ladder 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
5.3.3 Procedure to engage Auxiliary Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
5.3.4 Folding the hopper sides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
5.3.5 Unfold the Natural Fines Conveyor and fitting the belt troughs . . . . . . . . . . . . . . . . . . . . . . 105
5.3.6 Unfolding the main conveyor and Positioning into Working Position. . . . . . . . . . . . . . . . . . 107
5.4 Additional Initial Setup and Operation for Hanging Screen Options . . . . . . . . . . . . . . . . . . . . . . . . 108
5.4.1 Setting Up the Recirculation Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
5.4.2 Preparing the Stock pile Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
5.4.3 Unfolding the main conveyor and Positioning into Working Position. . . . . . . . . . . . . . . . . . 112
5.4.4 Preparing the Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4.5 Preparing the secondary screen box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
5.4.6 Preparing the primary Screen Box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
5.4.7 Preparing the Midsize transfer conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.4.8 Preparing the Recirculation Jack Legs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
5.4.9 Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
5.5 Machine operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.6 Machine Shut Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
5.6.1 Auto Stop Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
5.6.2 Preparing the machine for transport or for the machine to be moved to another location. .
123
5.6.3 Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
5.7 Location Of Emergency Stops On QI441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

6.0 Operation 127


6.1 Operation Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
6.2 Loading the feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.2.1 Avoid damage to equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6.3 Common Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.3.1 Construction, Demolition and recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.3.2 Minerals and Quarrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.3.3 Maximum Feed size for Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
6.4 Feed and Jams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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6.5 Operating the QI441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.5.1 Start-up Sequence For Running the Crusher . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
6.5.2 Auto Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
6.5.3 Automatic Mode - Recirculation System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
6.5.4 MMPRO S menu Flow chart in automatic Run mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
6.5.5 Manual Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
6.5.6 Feeder Load Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
6.5.7 Machine Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
6.5.8 Tail Level adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
6.5.9 Are Precautions Adequate?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
6.5.10 Diverter Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
6.5.11 Primary Screen Box Working Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
6.5.12 Fault Logs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
6.6 Clearing Crusher Chamber Jam’s. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
6.6.1 Managing Work Related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 147

7.0 Maintenance 149


7.1 Maintenance Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
7.2 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
7.2.1 Testing the Emergency stop function and Battery Isolator . . . . . . . . . . . . . . . . . . . . . . . . . 154
7.2.2 Belt Tension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
7.2.3 Maintenace to the CI421 Impactor using DC Maintenance Motor . . . . . . . . . . . . . . . . . . . . 158
7.2.4 Engine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.2.5 Radio Remote Control battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
7.2.6 Working at height hazard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.2.7 Air Cleaner Inspection, Daily Inspection Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.2.8 Air Cleaner Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
7.2.9 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . 164
7.2.11 Emptying the Fuel Filter Water Trap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
7.2.12 Special Considerations For Maintenance Or Repair with Welding . . . . . . . . . . . . . . . . . . 166
7.3 Hydraulic System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.3.1 Hydraulic Oil daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
7.3.2 Hydraulic Oil is added as follows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
7.3.3 Changing The Return Line Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
7.3.4 Changing the suction Filters and Hydraulic Oil.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
7.3.5 HPTO Clutch Hydraulic Oil daily check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7.3.6 HPTO Clutch adding hydraulic oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7.3.7 HPTO CLutch Lubrication tank Suction Filter change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
7.3.8 HPTO Oil filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
7.4 Track Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.4.1 Checking the Track Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
7.4.2 Tighten the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.4.3 Loosen the Tracks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
7.4.4 Track Drive Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
7.5 Tensioning Conveyor Belts on the Standard QI441 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.5.1 Tensioning the Natural Fines Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
7.5.2 Tensioning The Main Conveyor belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
7.6 Tensioning Conveyor Belts on the QI441 with Hanging Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.6.1 Tensioning the Fines Conveyor Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
7.6.2 Tensioning the Recirculating Conveyor and Stockpile Conveyor Belts . . . . . . . . . . . . . . . . 180
7.6.3 Tensioning the Oversize and Midsize Transfer Conveyor Belts . . . . . . . . . . . . . . . . . . . . . 181
7.6.4 Tracking the Conveyor Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
7.6.5 Removing and Installing Screen Media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
7.6.6 Maintenance Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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7.6.7 Hydraulic Oil Requirements for QI441 Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
7.6.8 Hydraulic Oil Requirements for HPTO Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.6.9 Lubricants and Fluids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
7.6.10 Greasing Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
7.6.11 Care of chrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

8.0 Trouble Shooting and Engine Warranty 197


8.1 Trouble Shooting Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.1.1 Who is at Risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.1.2 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.1.3 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
8.2 Machine Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.2.1 Engine Faults (Engine Control Unit) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
8.2.2 Engine Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
8.3 Using the Proportional Spool Valve System (PSVS) controls to Diagnose Hydraulic or Electrical Faults
202
8.3.1 Service Engineer Selection for PSVS Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.3.2 PSVS Diagnosis for Hydraulic or Electrical Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
8.4 Commissioning and Engine Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.4.1 Commissioning and Warranty Registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
8.5 CAT Register Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
8.5.1 CAT C Series Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

9.0 Spare Parts 209


9.1 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.1.1 Spare Parts illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.1.2 Ordering Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
9.1.3 Managing Work related Hazards with a Risk Assessment . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.1.4 When carrying out maintenance or adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
9.2 Machine Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.3 Top Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
9.4 Hydraulic Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
9.5 Vbelt Guard. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
9.6 Pre Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
9.7 Chassis Complete. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
9.7.1 Chassis Tower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
9.7.2 Crusher Drive Tensioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
9.7.3 Turnbuckle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
9.7.4 Jack Leg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
9.7.5 Oil cooler and Walkway assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
9.8 Maintenance Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
9.8.1 Interlock Kit - (881.0210-00) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
9.9 Impactor Assembly Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
9.9.1 Crusher Inlet Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 236
9.9.2 Diverter Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
9.9.3 Impactor Chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
9.10 Hydraulic Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242
9.11 Natural Fines Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 244
9.12 Powerunit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 248
9.12.1 Powerpack - Tier 3A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 250
9.12.2 Powerpack - Tier 3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259
9.12.3 Clutch Lube Tank. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 265
9.12.4 Diesel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 266
9.12.5 Hydraulic tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 267
9.13 Eriez Magnet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
9.14 Hopper Wing Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
9.15 Main Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272
9.15.1 Main Conveyor Lower Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

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Contents
9.15.2 Main Conveyor Upper Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
9.15.3 Main Conveyor Extension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278
9.16 Primary Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
9.16.1 Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
9.17 Pan Feeeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 286
9.18 HS System - Recirculating Oversize [ Option where Fitted ] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 288
9.18.1 Recirculation conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 290
9.18.2 HS System - Mounting Frame recirculating oversize. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295
9.18.3 Recirculation Fines conveyor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
9.18.4 Recirc product conv upper section complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 298
9.18.5 Recirc product conv lower section complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300
9.18.6 Recirculation Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 302
9.19 Stock Pile Conveyor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 310
9.20 Transfer Conveyor 1440-35-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
9.21 Transfer Conveyor 1442-35-00. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
9.21.1 HS System - Recirculating Mid & Oversize [ Option where fitted ] . . . . . . . . . . . . . . . . . . 316
9.21.2 Transfer Conveyor - Recirculating Over & Midsize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
9.21.3 Engine Filter Kits - CAT C13 TIER 3A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
9.21.4 Engine Filter Kits - CAT C13 TIER 3B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

10.0 Electrical and Hydraulic 323


10.1 Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
10.2 Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
10.2.1 Hydraulic Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346

11.0 OEM Section 351


11.1 OEM Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.1 CI421 Impactor Crusher Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.2 CI421 Impactor Crusher Maintenance Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.3 CI421 Impactor Crusher Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.4 CI421 Impactor Crusher Wear Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.5 Eriez Magnetic Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.6 Roxon Vibrating Feeder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.7 Crawler Tracks Operation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.8 M-PROS Control System Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352
11.1.9 Optional Extra’s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 352

6 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441

1.0 Safety Section - Introduction

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 7
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Safety qi441

1.1 The purpose of these instructions

The purpose of these instructions is to promote intended safe, proper and optimal use of Sandvik
products and t o help the user to identify , avoid and prevent hazardous situations a nd related
consequences.

These instructions must be followed along with any instructions given in local laws and regulations,
any orders given by local authorities and all protective measures specific for the site.

Read and understand the complete manual carefully and follow given instructions strictly. If there is
anything you do not understand, ask your employer or your local Sandvik representative to explain
it. All sections of this manual contain information which is vital for your safety. The manual must be
replaced immediately if lo st, damaged or unrea dable. For rep lacement copies, please co ntact
tsdaftermarket.mobiles@sandvik.com
and provide the machine serial nu mber, what type of manuals are req uired eg operators and
language version required.

The instructions set forth in the operator’s and other manuals are to be used as a part of the training
material during orientation. By following these instructions, safe practices will result, maintenance
cost and downtime will be minimised and the reliability and lifetime of the equipment will be optimised.

1.2 Identification of the product

1.2.1 Product type and serial number

The model and serial number of the product are shown on the identification plate.

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qi441 Safety

1.2.2 Product manufacturer

Business name and full address -

Sandvik Mining and Construction Mobile Crushers and Screens Ltd


Tullyvannon,
Ballygawley,
Co.Tyrone
Northern Ireland
BT70 2HW

Telephone number -

+44 (0) 28 8556 7799

Fax -

+44 (0) 28 8556 7007

Website -

www.miningandconstruction.sandvik.com

www.sandvik.com

Declaration of conformity

1.2.3 Manuals

Product documentation includes the following manuals:

• The operator's manual includes operating instructions, operator's safety considerations and
maintenance tasks for which an operator would be responsible. It does not include
maintenance procedures that should be performed with less than daily frequency.

• The maintenance manual includes the preventive maintenance schedule and a description of
all scheduled maintenance tasks. It also includes fluid and lubricant specifications and
capacities. It does not include occasional service, breakdown, or repair procedures.

• The parts manual includes part lists and illustrations for spare parts.

• The model and serial number are shown on the identification plate (refer to section, “Product
type and serial number” on page 8). Make sure that the model corresponds to the one given
on the cover of this manual.

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Safety qi441

1.2.4 How to identify the right manual for the product.

• operator's manual (e.g. Product model)

• maintenance manual (e.g. Product model)

• parts manual (e.g. product model + serial number)

1.2.5 Validity of the manuals

This manual, and especially the safety information is valid on ly, if no unauthorised changes to the
product are made.

Continuing improvement and a dvancement of product design might have ca used changes to your
product which are not included in this publication. Note also that if a third party has made changes to
the product after delivery from the manufacturer, this publication does not include information on
these changes or their influences on the product.

Whenever a question arises regarding your product, or this manual, please consult your local
Sandvik representative for the latest available information.

1.3 Copyright notice

This publication is co pyright of Sandvik Mi ning and Construction - © Sandvik Min ing and
Construction. It must not be copied, reproduced, or otherwise made available in full or in part to any
third party without Sandvik Mining and Construction's prior written consent.

All Rights Reserved.

1.4 Definitions

• Product: Machine, machinery, partly completed machinery, component or tool, including


related services.

• User: The owner, operator or authorised and trained person involved in the transportation,
installation, operation, maintenance and disposal of the product.

• Information for use: The information in this manual, the safety labels and signals on the
product and other related information used separately or in combination to convey information
to the user.

• Harm: Physical injury or damage to health. This is always in relation to people, not to
equipment or property.

• Hazard: Potential source of harm.

10 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441 Safety

• Risk: Combination of a probability of occurrence of harm and the severity of that harm.

• Risk of property damage: Combination of a probability of occurrence of property damage


and the severity of that property damage.

• Environmental risk: Combination of a probability of occurrence of environmental damage


and the severity of that environmental damage.

• Hazard zone: Any space within and/or around the product in which a person is exposed to a
hazard.

• Intended use of a product: Use of a product in accordance with the information provided in
the instructions for use.

• Reasonably foreseeable misuse: Use of a product in a way that is not intended by the
designer, but which may result from readily predictable human behaviour.

• Prohibited use: Any use which is not intended use, especially use that is specifically
prohibited in the information for use or use which is plainly dangerous.

• Safe working procedures: Practices and methods developed for the users by their employer
for work to be performed. It details how specific risks in the workplace will be managed, taking
into account information for use supplied with the product as well as local acts, laws and
regulations.

• Safeguard: Guard or protective device.

• Guard: Physical barrier, designed as part of the product, to provide protection.

• Protective device: Safeguard other than a guard, which reduces the risk either alone or in
conjunction with a guard; e.g. interlocking device, hold-to-run control, limiting device.

• Emergency stop: Function which is intended to 1) avoid dangerous situations or to reduce


existing hazards to persons and damage to product or work in progress 2) To be initiated by a
single human action.

• Emission value: Numerical value quantifying an emission generated by a product (e.g. noise,
vibration, hazardous substances, radiation).

• Exposure value: Quantifies the exposure of persons to emissions when the product is in use.
Exposure values can be estimated using the emission values.

• Respirator: Approved respiratory protective device.

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 11
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Safety qi441

12 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441

2.0 Safety Section - Safety and


Environmental Instructions

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 13
ID:QI441.en.ver.1
Safety qi441

2.1 Safety labels and signals

This section includes explanations of safety symbols, signs, signals and labels used on the product
and information for use.

2.1.1 Signal words

The following signal words and symbols are used to identify safety messages in these instructions:

DANGER
The signal word “DANGER” indicates a hazardous situation which, if not avoided, will result in death
or severe injury.

WARNING
The signal word “WARNING” indicates a hazardous situation which, if not avoided, could result in
death or severe injury.

NOTICE
The signal word “NOT ICE” indicates a situation wh ich, if not a voided, could result in damage to
property or environment.

2.1.2 General hazard symbol

This general hazard symbol identifies important safety messages in this manual.

When you see this symbol, b e alert; your safety is involved. Carefully read and understand the
message that follows, and inform other users.

14 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441 Safety

2.1.3 Symbols for mandatory actions

Mandatory actions symbols specify actions to be taken to avoid a hazard. Mandat ory actions are
indicated by white symbols on a blue background.

Wear Safety Gloves Wear Eye Protection Wear Safety Helmet

Wear Safety Harness Wear Ear Protection Wear Safety Boots

Wear Close Fitting


Read the Manual Wear High Visibility Vest
Overalls

Disconnect Power Switch Off and Lockout


Wear Respirator
Source From Supply Equipment

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 15
ID:QI441.en.ver.1
Safety qi441

2.1.4 Symbols for prohibited actions

Prohibited action symbols indicate actions which are prohibited in order to avoid a hazard. Prohibited
actions are indicated by a red circle with a red diagonal line across the circle. The action which is
prohibited will always be in black.

No Climbing No Smoking Do Not Touch

Limited or Restricted
No Open Flames Do Not Weld
Access

Do Not Remove Safety


Guard
2.1.5 Hazard symbols

Hazard symbols are indicated by a yellow triangle with black symbols and black frames.

Crushing Hazard -
Crushing Hazard - Feet Chemical Burn Hazard
Hands

Electrical Shock/
Electrical Hazard Entanglement Hazard
Electrocution Hazard

16 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441 Safety

Entanglement Hazard Falling Hazard Falling Load Hazard

Hazardous or Poisonous
Flammable Hazard Flying Material Hazard
Material Hazard

Silica or Other Dust


Lifting Hazard Skin Injection Hazard
Hazard

Trip Hazard Magnet Hazard

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 17
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Safety qi441

2.1.6 Labels on the product

Safety labels communicate the following:

• The severity level of the risk (i.e. signal word ”DANGER” or ”WARNING”)

• The nature of the hazard (i.e. the type of hazard – cutting parts, high pressure, falling objects,
dust, live parts, etc)

• The consequence of interaction with the hazard (i.e. cut, injection, crushing, explosion,
electrocution etc)

• How to avoid the hazard

IMPORTANT! Keep th e safety labels clean and visible at all times. Check th e condition of
safety labels daily. Safety labels and instructions which have fade d, been damaged, been
painted over, come loos e or tha t do not meet the legi bility requirements for safe viewing
distance, must be replaced before operating the product.

Replacement of labels -

For replacement labels, please contact:


tsdaftermarket.mobiles@sandvik.com and provide the machine seri al number, label part codes
and language version required.

18 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441

12-55-0206
12-55-0283

12-55-0389 12-55-0398 12-55-0390 12-55-0005 12-55-0001


12-55-0001 12-55-0004 12-55-0004 12-55-0004
12-55-0408

ID:QI441.en.ver.1
12-55-0405 12-55-0387

12-55-
12-55-0283

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
12-55-0396

12-55-0408
12-55-

12-55-0388
12-55-0005 12-55-0001 12-55-0004 12-55-0387 12-55-0295 12-55-0366 12-55-0405

19
Safety
qi441

12-55-0283 12-55-0393
12-55-0071
12-55-0364 12-55-0365
12-55-0001 12-55-0004 12-55-0005 12-55-0001 12-55-0004
12-55-0001 12-55-0004 12-55-0379

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
12-55-0389
12-55-0387 12-55-0283 12-55-0283
12-55-0398 12-55-0408

ID:QI441.en.ver.1
12-55-0004
12-55-0405
12-55-0206
12-55-0382
12-55-0386 12-55-0410
12-55-0379 inside cabinet
12-55-0410
12-55-0283
12-55-0005 12-55-0001 12-55-0387 12-55-0372 12-55-0295 12-55-0071 qty 2 12-55-0362 12-55-0410

20
Safety
qi441

12-55-0407

12-55-0404

12-55-0003 12-55-0002

ID:QI441.en.ver.1
1
00:00:10

4
4

4i
I
12-55-0007 12-55-0006 12-55-0397
4ii 4iii

12-55-403

12-55-0403

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
12-55-0011
12-55-0006

12-55-0361 12-55-0359 12-55-0360 12-55-0008


12-55-0044 12-55-0246 12-55-0225

21
Safety
qi441

12-55-0408
12-55-0377
12-55-0044 12-55-0001 12-55-0004
12-55-0408

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
12-55-0405
12-55-0378
Additional Stickers when Hanging Screen Option is Fitted

ID:QI441.en.ver.1
12-55-0405 12-55-0408
12-55-0381 12-55-0369 12-55-0363 12-55-0367
12-55-0323 12-55-0370 12-55-0409 12-55-0368 12-55-0371
12-55-0322

22
Safety
qi441

12-55-0001 12-55-0004 12-55-0044 12-55-0408

ID:QI441.en.ver.1
12-55-0373 12-55-0374

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
12-55-0405

12-55-0375 12-55-0376 12-55-0408 12-55-0322 12-55-0323

23
Safety
Safety qi441

2.1.7 Visual and audible signals

Sirens and Beacons:

There are two siren’s and two beacon’s on the QI441.

When the key is turned to start the QI441 engine, the siren will so und and the beacon will flash for
ten seconds before the engine will crank to start.

When the track controller [umbilical or remote] is switched on and the required control panel button
is pressed to track the machine, the siren will sound and the beacon will flash for seven seconds, in
which time the machine will not be able to be tracked. The siren and beacon will then be on
continuously once the tracking mode is selected.

These visual and audible safety devices should be checked at the start of every working day. For their
location refer to “Complementary protective measures” on page 37.

2.2 User obligations

WARNING
IGNORING INSTRUCTIONS HAZARD

If you do not understand any information related to your duties in the


operator’s or maintenance manual you MUST make sure that you get
clarification from a person who is well trained with regard to the task
you want to do. When necessary, you or your representative must
contact a Sandvik representative to seek clarification as to how you
should do the task.

The safe use of a product depends on, amo ng other things, a combination of the design and
construction measures taken by the ma nufacturer, the skills of the operators and prot ective
measures taken by the user. Instructions are an essential and integral part of the product and they
must be always available for users. It is important to pass on the information for use to any
subsequent user of this product. Specify the place of manual on the product.

Sandvik prohibits the consumption of drugs and/or alcohol or any other substance likely to impair
judgement while using, being in the hazard zone of, or supervising the use of a Sandvik product.

Safety information covers the following : transport, assembly, installation, commissioning, use,
settings, operation, cleaning, troubleshooting, maintenance and disposal of machinery. If you need
more detailed instructions, you must contact your local Sandvik representative.

As part of ensuring the safe use of the product, you as the user are responsible for the following:

• Use of Personal Protective Equipment (PPE)

• Scheduled testing and maintenance of safeguards and protective devices

• Provision and use of additional safeguards

24 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441 Safety

• Regular training regarding site safety and safe working procedures

In addition, you must always be familiar with the following:

• Site organisation and supervision

• Workplace safety, including safe working procedures

• Permit-to-work systems

All near-miss incidents and accidents where a Sandvik product has been involved must be reported
to your local Sandvik representative without a delay. See also the section, “Incident reporting” on
page 52.

The following safety guidelines apply to each person working with the product or in the vicinity of the
product. Every single person is responsible for his or her own safety and for the safety of his or her
colleagues. In case of violation of any safety guidelines or regulations, everyone has a duty to warn
others and report near misses or any safety violation to the responsible supervisor.

2.2.1 Managing work related hazards

The user must always perform a local risk assessment befo re every new task, e.g. work phase or
shift. This assessment, also known as a Real Time Hazard Analysis, ensures that the user stops and
thinks about what he or she is going to do before starting to work:

• Identify potential hazards that could impact you, your colleagues, the environment, your
product and/or work method while you are performing the task.

• Assess the risks and implement the actions needed to eliminate or reduce the risks.

Only competent persons may carry out operation and other tasks. The employer must:

• Provide training and orientation

• Validate training methods

• Verify competence and skills

• Monitor and evaluate user performance regularly

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 25
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2.2.2 Scheduled safety inspections and preventive maintenance

It is important to thoroughly inspect the product before use to make sure it is safe to operate. Look
for defects and damage before any operation so that any problems can be reported and fixed. For
more information, see the section, “6.0 Operation” on page 127, in the operator’s manual.

Scheduled maintenance is an essential pr ocedure to ensure and maintain safety and performance
of the product. Follow the specified instructions for the maintenance and inspection of product. For
more information, see section, “7.0 Maintenance” on page 149, in Maintenance Manual.

WARNING!

Use of unauthorised parts present an uncontrolled risk and could cause death or
severe injury. The use of unauthorised parts will also invalidate warranty. It is the
user’s responsibility to use only authorised parts as listed in the parts manual.

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qi441 Safety

2.2.3 Personal protective equipment

Operators and anyone in the vicinity of the product MUST we ar approved personal protective
equipment, which includes but is not limited to:

Safety helmet

Eye-protector

Hearing protectors

Close fitting overall

Safety footwear

Protective gloves

High visibility vest / jacket

Respirator

Do not wear loose clothing or jewellery that can get caught on controls or pulled into moving parts of
the product.

Tie back long hair. Long hair can get entangled, which could cause death or severe injury.

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Safety qi441

2.3 Product limitations

2.3.1 Intended use

Refer to “6.3 Common Applications” on page 131.

2.3.2 Foreseeable misuse

The QI441 has been designed with selected componen ts to op erate at a op timum level of
performance. The user must never limit or bypass or override any safety aspect of the product (e.g.
removing a guard). Refer to “6.3 Common Applications” on page 131.

2.3.3 Prohibited use

• Use which is not in accordance with intended as described in “2.3.1 Intended use” on page
28.

• Bypassing or overriding a safety device or a safety feature of the machine for any reason.

• Use of product without required and approved personal protective equipment.

2.3.4

2.3.5 Maximum inclination angles during tramming and parking

WARNING
TIPPING HAZARD

Never exceed the specifies maximum inclination angles. The maximum


angles are allowed only when the booms are in the tramming position.

The rig must not be trammed or parked on a slope that exceeds the maximum
inclination angles.

This equipment must never be tracked on gradients that are more than:

10 degrees side tilt or 20 degrees front tilt.

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qi441 Safety

2.3.6 Maximum inclination angles during operation

The QI441 is designed for ope ration on a solid, level surface. It is important that the machine is
placed on solid ground that is capable of carrying the weight of the machine and that the machine is
placed on level ground. An appropriate site must be identified prior to delivery and unloading of the
machine.

2.3.7 Modifications

WARNING
MODIFICATION HAZARD

Unauthorised modifications could lead to d eath, severe injury or property


damage.

Always contact a Sand vik representative in order to get adva nce written
approval for any modification

All modifications and corrections not authorised in the product manuals or which may af fect the
maintenance, operation, safety, and availability of the product need to be approved in writing by the
manufacturer before implementation. Approval requires careful risk assessment taking into
consideration any new risks that the modifications may bring.

Changes and modifica tions without proper risk assessment, eliminat ion or red uction of risk and
without appropriate safety measures may lead to death, serious personal injuries or damage to
property or environment. Unauthorised modifications will also void the warranty.

If modifications and alterations that affect the maintenance, operation, safety, and usability of the
product are made without the written permission of the manufacturer, the manufacturer is not
responsible for any incidents resulting in death, injury, or property damage b rought about by such
modifications and corrections.

If a modification or correction as described above has been implemented without the manufacturing
organisation’s permission, it’s effect on warranty liability will be considered case-by-case. Thus, the
warranty application may be rejected altogether.

Should you consider a modification or alterations necessary, you must contact the organisation that
manufactured and designed the p roduct. No mo dification is permitt ed unless yo u first obt ain the
written approval of the manufacturer.

In order to plan and implement the modification you must deliver adequate documentation:
• Product model/type

• Serial number of product

• Description of the modification or correction

• Related blueprints

• Related photos

• And other material if necessary

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Safety qi441

2.4 Hazard zones


Limit access to the equipment and its surrounds by erecting barrier guards to reduce the risk of other
mechanical hazards, falling loads and ejected materials.

2.4.1 Exclusion zone for QI441

HAZARD AREA
20m

DO NOT ENTER

Material Ejection Area


DO NOT

DO NOT
HAZARD

HAZARD
Material
Ejection

Material
Ejection
ENTER

ENTER
AREA

AREA
Area

Area
ACCESS

PANEL
ZONE

TROL
CON-
TO
DO NOT ENTER
HAZARD AREA

Material Ejection
Area

personnel NOT operating the machine


Material Ejection Area

from any point of the machine for


5m distance from

20m EXCLUSION ZONE


HAZARD

DO NOT
ENTER
AREA
feeder

NOT TO SCALE
20m

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qi441

20m
HAZARD AREA
DO NOT ENTER

Material Ejection
Area

HAZARD AREA
DO NOT ENTER
20m
Material Ejection
HAZARD
Area AREA
DO NOT
ENTER

Material
5m distance from Ejection
Area
feeder

HAZARD
AREA
DO NOT

ID:QI441.en.ver.1
HAZARD AREA
DO NOT ENTER

ENTER
Material Ejection Area

ACCESS
HAZARD
ZONE
Exclusion zone for QI441 with Hanging Screen [HS] Option

AREA
Material Ejection Area DO NOT
ENTER TO

Material CONTROL HAZARD AREA


Ejection DO NOT ENTER
Area PANEL
Material Ejection
Area
HAZARD AREA
DO NOT ENTER

Material Ejection

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
20m EXCLUSION ZONE Area
from any point of the machine for
personnel NOT operating the machine

NOT TO SCALE

31
Safety
Safety qi441

2.5 Safeguarding

2.5.1 Guards

WARNING
TAMPERING HAZARD

Bypassing or overriding of a safeguard or a device could cause death or


severe injury.
Do not make any alterations to protective devices. Make sure that they are in
place and work properly before operating the machine.

Drive couplingt
Snub drum guard

guard

Jack leg cover plate

Track covers
Main Conveyor
Skirting guards

* All panel doors are also considered guards


Main Conveyor tunnel
and side face guards

Main Conveyor Lower section


guarding and tunneling
Engine surround

Side Conveyor Return


Oil cooler guard

roller guard
Hopper door lift ram
Primary feeder
motor guard

guards

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qi441

Hopper door lift ram


Drive coupling guards
Main Conveyor Prescreen drive
guard Engine surround shaft guard
Skirting guards

ID:QI441.en.ver.1
Snub drum guard

Return roller guards


Main Conveyor Track covers Drive belt guard
Return roller guards
Main Conveyor tunnel Drive coupling Jack leg cover plate

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
and side face guards guard

* All panel doors are also considered guards

33
Safety
Safety

34
Drive Conveyor Drive Coupling
guard guards Skirting guards

ID:QI441.en.ver.1
Additional guards when the Hanging Screen Option is fitted

Drive Coupling
guards

Tail drum guards Face guards tunnel guards

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
Return roller guards

* All panel doors are also considered guards


qi441
qi441

Conveyor Head
Skirting guards Tunnel guards Return roller guards Skirting guards Section guards

ID:QI441.en.ver.1
Additional guards when the Hanging Screen Option is fitted

Return roller guards Tail drum guards

Face guards Conveyor guards

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
* All panel doors are also considered guards

35
Safety
Safety qi441

2.5.2 Protective Devices

ISOLATOR ON

ISOLATOR OFF

a. Prior to opera tion, all safety devices (con trol devices or guards) temp orarily
removed for se t-up, maintenance or repair purposes MUST be refitted and
checked immediately upon completion of the maintenance and repair work.

b. To avoid serious personal injury or death, NEVER operate the equipment with
safety devices or guards removed or unsecured.

c. ALWAYS report any defects regarding guards, safety devices or control devices.

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qi441 Safety

2.6 Complementary protective measures

2.6.1 Use of Emergency stop function

There are five Emergency Stops on the QI441 and one engine kill switch on the remote control.

BEACON SIREN

SIREN BEACON

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Safety qi441

Control Panel
Emergency Stop

Emergency Stop
Reset Button

Engine Kill Switch

Umbilical Tracking
Lead Engine Kill
Switch

38 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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qi441 Safety

2.6.2 Emergency exit

The QI441 is not permitted to operate inside buildings or dwellings. The area surronding the QI441
must always be clear of obsructions eg containers, unnecessary stockpiles etc.

2.6.3 Safe access to machinery and three point support

No climbing on the machine is allowed.

The maintenance platforms should never be used to observe the machine operation.

Three point support is NOT needed on the QI441.

a. Falling from and/or onto this equipment could result in death or serious injury.

b. NEVER climb on the equipment while it is in operation or use equipment parts as


a climbing aid.

c. ALWAYS keep the area around the equipment clear of debris and trip hazards.

d. Beware of moving haulage and loading equipment in the area of the equipment.

e. For carrying out overhead assembly work, ALWAYS use specially designed or
otherwise safety-oriented ladders and working platforms.

f. ONLY use walkways/platforms provided on the eq uipment. ALWAYS perform


work from an approved, safe and secure platform.

g. When reaching any points 2m (approximately 6 feet) or more ab ove the ground
level, ALWAYS use CE certified safety harness.

h. Keep all handles, steps, handrails, platforms, landing areas, and ladders free from
dirt, oil, snow and ice.

a. This equipment MUST be isolated prior to cleaning.

b. DO NOT direct power washers near or into control boxes and devices.

c. After cleaning, examine all fuel, lubricant, and hydraulic fluid lines for leaks, loose
connections, chafe marks and damage. Any defects found MUST be repaired
immediately.

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Safety qi441

2.6.4 Isolation and energy dissipation

Lockout and Tag Procedure:

Utilise the procedure below whenever the QI441 is being operated under alternate power, or under
any condition in which shutting off the engine and removing the ignition key does not completely cut
power to the machine. Under such circumstances, to properly immobilise the QI441:
• Position all hydraulic controls in the neutral position

• Ensure that all supports and slide stops are securely fixed in position
• Switch off machine ignition and remove ignition key

• Turn off Isolator Switch (See Photo Below)

• Lockout the isolator with a padlock and use a Tag to detail the work being done.
• User must retain padlock key on his/her person during immobilisation

ISOLATOR ON

ISOLATOR OFF

Note! The above procedure MUST be utilised to safely immobilise the QI441 when it is under
alternate power. Failure to utilise the above procedure may result in damage to the
QI441, serious personal injuries or death.

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qi441 Safety

Removal of the Lockout and Tag:

Once the work has finished; remove ONLY your lock and tag, as other people may be working on the
machine at the same time.

The machine can only be started when the last lock and tag is removed.

DANGER
IMPACT HAZARD

Before moving the machine, visually check to make sure no one is standing in
the surrounding area.

Note! Refer to Start-up Sequence for Running the Machine, refer to “5.2.2 Engine Start-up
Sequence” on page 94.

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2.6.5 Fire risk control measures

WARNING
FIRE AND EXPLOSION HAZARD

Explosion hazard can exist in addition to the first hazard.

Ignition sources like smoking, open flames, welding work and sparks together
with combustible materials like fuel, can cause fire and if n ot avoided, could
lead to death or severe injury.

Ignition sources are prohibited in the vicinity of the machine ready for operation or in
operation.

During maintenance appropriate fire prevention and protection measures must


be followed including but not limited to trained personnel, proper fire
extinguishing equipment and age nts. Before any mai ntenance or rep airs
requiring ignition sources like welding or fla me cutting, a proper risk
assessment must be carried out prior to the start of the work to control the risk.

Smoking and open fire a re prohibited in th e vicinity of the p roduct. Access to all fire -fighting
equipment must be granted at all times, especially during maintenance and repair works.

All fire-fighting equipment musto be inspected and serviced regularly according to local regulations.
Damaged fire-fighting equipment and used fire extinguishers must be replaced immediately.

Know the various types of fires and the appropriate fire fighting methods. Be aware that various fires
must not be extinguished with water. In most cases special extinguishing agents, dry powders or
deoxygenating are required.

All personnel must be trained regularly in fire-fighting methods in cooperation with local authorities
and rescue organisations. In case of fire, the fire alarm must be activated and all available personnel
must contribute in the fire-fighting according to the predetermined fire plan of the workplace.

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2.7 Protection against emission hazards

2.7.1 Noise

DANGER
NOISE HAZARD

Noise level emitted by the machine exceeds 80 dB(A). Continuous exposure to


noise will cause hearing impairment.

Always wear approved hearing protection.

Ear protection must be worn if you are within 10 meters (approximately 33 feet) of
the machine when the engine and other parts of the machine are running.

3 Metre (9'9") Radius 96dB

2 Metre (6'6") Radius 99dB

1 Metre (3'3") Radius 112dB


86dB

90dB

94dB

96dB

92dB

The above diagram indicates the measured noise levels at a measured distance; i.e. 3 m
(approximately 12 feet) - 96 dB indicates that at 3 meters the sound measured was 96 decibels. The
readings were with all systems running situated on the factory assembly line. The product and local
conditions will affect the noise levels.

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2.7.2 Vibration
WARNING! VIBRATION HAZARD!

Exposure to vibration could cause severe health effects. Follow the maintenance
schedule and keep the mac hine in good operatin g condition. Participate in the
health surveillance and training programs offered by your employer.

2.7.3 Dust

DANGER

DANGER
DUST HAZARD

Breathing dust will cause death or severe injury.

Always wear approved respirator.

If machine is equipt with a dust suppression system make sure the dust suppression
system is working properly.
Breathing or inhaling dust particles will cause death or severe injury. Always work with a respirator
approved by the respirator manufacturer for the job you are doing. It is essential that the respirator
that you use protects you from the tiny dust particles which cause silic osis and which may cau se
other serious lung diseases. You should not use the product until you are sure your re spirator is
working properly. This means the respirator must be checked to make sure that it is clean, th at its
filter has been changed, and to othe rwise make sure the respirator will protect you in the way it is
meant to.

In any workplace where respirators are necessary to protect the health of the employee, theemployer
must establish and implement a written re spiratory protection program with worksit e-specific
procedures and elements including but not limited to the selection of respirators, proper usage,
maintenance and care, cleaning and disinfecting and training.

Make sure the du st suppression system in your equip ment is working properly. If the dust
suppression system is not working properly, stop working immediately.

Regularly clean your working environment properly to minimize the dust level in the air. Always make
sure dust has been cleaned off your boots and clothes when you leave your shift.

Respiratory silica dust is a hazard, which requires special attention. The smallest particles of dust are
the most harmful. They may be so fin e that you cannot see the m. Remember, you must protect
yourself from the danger of breathing or inhaling dust.

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2.8 Emergency procedures and methods for unblocking

Blockage or Malfunction:

In the event of mate rial blockage, any ma lfunction or operational difficulty, stop the
equipment and lockou t immediately. Repair any defects or hazardous cond itions
immediately. Refer to “2.6.4 Isolation and energy dissipation” on page 40.

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Safety qi441

2.9 Safety considerations for maintenance

Before carrying out any maintenance read and understands the maintenance instructions. Make sure
that you ha ve the skills a nd authorisation needed before starting any maintenance work. The
maintenance instructions support maintenance personnel performing preventive maintenance for the
product. The maintenance instructions also pro vide information for main tenance and operating
personnel on scheduled inspections of components and installed equipment.

Make sure all necessary machinery isolations (Refer to “2.6.4 Isolation and energy dissipation” on
page 40) have been carried out prior to commencing any maintenance work. Before carrying out any
maintenance work make sure that necessary original spare parts or materials are available, or can
be ordered and supplied in time to meet the work schedule. Note all completed maintenance activities
in a maintenance log or maintenance program.

Daily inspections and tasks allowed for op erators (which do not require sp ecial skills) are in the
Maintenance Chapter refer to “ 7.0 Maintenance” on page 149.

Any tasks not mentioned in this chapter should not be attempted by operators.

• Hydraulic Maintenance

a. Work on hydraulic equipment must be carried out by pe rsons having special


knowledge and experience of hydraulic systems.

WARNING
Splashed oil creates the risk of a fire, which could result in death or serious
injury.

Check all lines , hoses a nd screwed conne ctions regularly for leaks or other
damage.

Repair damaged lines, hoses, or screwed connections IMMEDIATELY

b. ALWAYS relieve pressure from the hydraulic system before carrying out any kind
of maintenance or adjustment.

c. BEFORE carrying ou t any repair wo rk, depressurise all syst em sections and
pressure pipes (i.e. hydraulic system, compressed a ir system, etc.) requiring
removal, in accordance with the specific instructions for the unit concerned.

d. Hydraulic and compressed air line s MUST be laid and fitted properly. Make sure
that no connections are interchanged. The fittings, lengths and quality of the
hoses MUST comply with the technical requirements.

e. ONLY fit replacement components of a type recommended by the manufacturer.

f. ALWAYS practice extreme cleanliness when servicing hydraulic components

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DANGER
Hydraulic fluid under pressure can penetrate the skin, which will result in death
or serious injury.

If fluid is injected under the skin, it must be surgically removed or gangrene will
result. GET MEDICAL HELP IMMEDIATELY.

ALWAYS use a piece of cardboard to check for leaks. DO NOT USE YOUR HAND

Battery Maintenance

a. ALWAYS disconnect b attery leads before carrying out any ma intenance to the
electrical system.

b. Recharge the battery in a well ventilated area.

c. The battery contains sulphuric acid, an electrolyte which can cause severe burns
and produce explosive gases.

d. AVOID contact with the skin, eyes or clothing.

e. Smoking is PROHIBITED when maintaining the battery.

f. ALWAYS wear appropriate personal protective equipment.

Electric maintenance

a. External Considerations and Hazards

When working with the equipment, maintain a safe distance from overhead electric lines. If overhead
cables are in the area, a risk assessment MUST be completed prior to operating the equipment.

DANGER
Contact with overhead electric lines will cause death or serious injury.

If your equipment comes into contact with a live wire, you MUST:

• Vacate the area;

• Warn others against approaching and touching the equipment;

• Report the incident and have the live wire shut off.

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b. Machine - Electrical

1. Work on the electrical syste m or equipment MUST ONLY be carried out by a


skilled and qualified electrician or by specially instructed personnel under the
control and supervision of such an electrician and in accordance with applicable
electrical engineering rules.
2. Before starting any maintenance or repair wo rk, the power supply to the
equipment MUST be isolated. Check the de-energized parts to make sure they do
not have any power. In addition to insulating any a djacent parts or elements,
ground or short circuit them to avoid the risk of electrical shock.
3. The electrical equipme nt is to be inspected and checked at re gular intervals.
Defects such as loose co nnections or scorched or otherwise dama ged cables
MUST be fixed immediately.
4. Use ONLY original fuses with the specified current rating. Switch off the
equipment IMMEDIATELY if trouble occurs in the electrical system.
5. This equipment is wired on a negative earth. ALWAYS observe correct polarity.

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2.10 Environment

2.10.1 Decommissioning

Hazardous Substances:

a. MAKE SURE that correct procedures are formulated to safely handle hazardous
materials in strict accorda nce with the manufacturer's instructions and all
applicable regulations by correctly ide ntifying, labelling, storing, using and
disposing of the materials.

b. A full list of Hazardous Substances associated with this equipment can be found in
the appendix of this document.

Warning Concerning Crystalline Silica And Similar Particulates:

• The QI441’S operation may produce dust containing crystalline silica or other potentially
harmful particulates. ALWAYS utilize appropriate and properly-fitted and approved Personal
Protective Equipment, (e.g. respirators). Refer to “2.2.3 Personal protective equipment”
on page 27.

• DO NOT linger in areas where dust is produced, blown or otherwise found. NEVER inhale
dust produced by the operation of the QI441.

Note! Inhalation of crystalline silica dust is potentially harmful to human health, and may
result in serious pulmonary disease or other deleterious chronic lung obstruction,
serious personal injuries or death.

2.10.2 Dismantling

Replacement & Removal of Components:

a. ALWAYS observe handling instructions itemised in this man ual, the Original
Equipment Manufacturer's manuals, or the spare parts suppliers' instructions.

b. NEVER allow untrained staff to attempt to remove or replace any pa rt of the


equipment.

c. The removal of large or heavy components without adequate lifting equipment is


PROHIBITED.

d. To avoid the risk of accidents, individual parts and large assemblies being moved
for replacement purposes should be ca refully attached to lift ing tackle and
secured. ONLY use suitable and technically a dequate lifting gear supplied or
approved by Original Equipment Manufacturer.

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e. NEVER work or stand under suspended loads.

f. KEEP AWAY from the feeder hopper and product conveyor discharge, where
there is risk of serious injury or death from contact with ejected debris.

g. LIMIT ACCESS to the equipment and its surrounds by erecting barrier guards to
reduce the risk of residual mechanical hazards, falling lifted loads, and ejected
materials.

2.10.3 Disposal
This equipment MUST ONLY be disposed at a specialist machine breaker

Handling And Disposal Of Hazardous Components And Materials

• The QI441’s battery contains sulphuric acid, which can cause severe burns, and produces
explosive gases. Inspect the machine’s battery regularly, and assure that it is properly
connected and maintained. NEVER allow battery parts to come into contact with unprotected
skin, eyes or clothing, use Personal Protective Equipment, refer to “2.2.3 Personal
protective equipment” on page 27. NEVER attempt maintenance or repair to the QI441’S
battery while the battery is connected.

• The QI441 includes an internal combustion engine, which produces exhaust fumes containing
potentially harmful gases and particulates. NEVER operate the machine’s engine in an area
lacking adequate ventilation, whether indoors or outside.

• Prior to welding, cutting, or grinding, ALWAYS assure that dust and other flammable
substances are removed from the work site. ALWAYS assure that the area where welding,
cutting or grinding is conducted is properly ventilated. Failure to observe these precautions
may increase the risk of explosion or fire, and may result in serious personal injuries or death.

• Keep flammable materials, chemicals, etc. away from the QI441 at all times.

Special Considerations Concerning Dust Disposal:

• ALWAYS utilize appropriate and properly-fitted Personal Protective Equipment (e.g.


respirators). Refer to “2.2.3 Personal protective equipment” on page 27.

• Always dispose of dust produced by the operation of the QI441 by applying water, placing
dampened dust in a marked, sealed container, and removing it from the work site.

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• NEVER disperse dust by blowing it; doing so mayexacerbate dusty conditions in the proximity
of the QI441, and may also cause dust to enter areas where unprotected persons may be
working, creating an increased risk of injury or death.

• ALWAYS assure that dust is removed from clothing, boots, etc. before leaving the work site.

• Liquids such as oil, fuel and battery liquids cause pollution. Follow the local, regional and
national regulations for waste disposal.

• Avoid running the engine at idle if it is not needed. Avoid unnecessary exhaust fumes.

• Observe the law in your country when disposing used machine components.

2.11 Potential product related hazards identified by the user

Operational Safety Considerations:

• Ensure that a copy of all operating instructions, including the Engine Operations Manual, is
kept current and maintained with the QI441 at all times. If the manual is unavailable obtain a
replacement from Sandvik.

• Operators MUST read and understand all operating instructions, and must always work
utilising indicated safety precautions and procedures.

• Operators and anyone in the area of the QI441 must ALWAYS use appropriate Personal
Protective Equipment, refer to “2.2.3 Personal protective equipment” on page 27.

• Operators MUST be familiar with and understand all warnings and labels affixed to the QI441.
Failure to do so may result in serious personal injuries or death. If warnings or labels are
damaged or illegible, operators must notify management immediately and urgently obtain
replacements.

• ALWAYS ensure, prior to operation of the QI441, that all safety devices are in place and
operational.

• If in doubt concerning the efficient, proper or safe operation of the QI441, contact your
Sandvik Dealer.

• Perform tasks only when safety is ensured.

• Contact your supervisor and local Sandvik representative.

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2.12 Incident reporting

Product safety issues to be rep orted are events where a product manufactured by Sandvik Mining
and Construction has been involved in an accident or near-miss incident. Safety-related feedback,
such as, unauthorised modifications, missing manuals and safety labels, negligence of maintenance
or misuse shall be reported to your local Sandvik representative as well.

Reporting is mandatory to ensure safe working conditions for employees, to provide information for
the risk assessment process and to initiate product improvements.

Contact your local Sandvik representative to report safety issues, such as those mentioned above.

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3.0 Transport &Technical Data

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Transport and Technical qi441

3.1 Transport

3.1.1 Special Considerations For Transport Of The QI441

• Do not attempt to transport the QI441 utilising a vehicle not specified for hauling
at least the listed gross weight of the machine. Failure to use transportation with
sufficient hauling capacity may result in damage to the QI441 and the hauling
vehicle, and may result in serious personal injuries or death.

• ALWAYS observe applicable local and national regulations concerning the


transportation of heavy equipment. Ensure that all appropriate permits, licenses
and endorsements are obtained and maintained before transporting the QI441.

3.1.2 Machine Preparation for Transport

Follow the procedure for preparing the machine for shut d own, refer to
WARNING “5.6 Machine Shut Down” on page 120.

Before attempting to set-up the machine ensure that the operator has read
and fully understood this and all the preceeding sections in the manual

DANGER
WORKING AT HEIGHT HAZARD
Falling may cause injury or death.
Always use a secure platform. Make sure correct procedures are followed FOR
the tasks that are done at height.

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3.1.3 Folding the main conveyor and Positioning into Transport Position

a.Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102)
to raise the main conveyor slighty to lift the weight off the locating pins by operating hydraulic control
HC6 refer to “4.3.2 Hydraulic Control Banks” on page 86

Locating Pin

Ladder fix
Point

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.

c. Attach the ladder [supplied] into the l adder fix p oint or use a secure platform to
remove the locating pin on each side. Remove the ladder

Failure to remove the ladder will result in damage to the ladder as the main
NOTICE coveyor will be lowered in the next operation.

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d. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102) to fold down the main conveyor by operating hydraulic control HC6 refer to “4.3.2 Hydraulic
Control Banks” on page 86

3.1.4 Folding the Natural Fines Conveyor and removing the belt troughs

a. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. . Remove the Belt troughs out of the mid section of the
Natural Fines Conveyor.

Remove these
items first

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b. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102) to raise the natural fines conveyor off the slide stop, b y operating the hydraulic control lever
HC1 Refer to “4.3.2 Hydraulic Control Banks” on page 86.

Slide stop top


position
HC2
locating pin

c. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.

d. Remove locating pin from slide stop at the top and relocate the slide stop to the
bottom postion and re-insert locating pins.

e. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102) to fold the natural fines conveyor down to the slide stop, by operating the hydraulic con trol
lever HC1

f. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Attach th e rachet t orque arm with the two locat ing pins. If
necessary adjust the torque arm length to allow the locating pins to be inserted.

Locating
pins

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3.1.5 Folding the hopper sides

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102. Raise the left and right hoppper sides until their weight is off the wedges by operating hydraulic
control levers HC2 Refer to “4.3.2 Hydraulic Control Banks” on page 86 .

Insert the
Wedges

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform if needed, use a additional supervisor
to remove the two wedges (see picture above).

c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102. Using a secure platform if needed, an additional supervisor is required to
guide the side hopper props outwards to fold down past the support plate by operating
hydraulic control levers HC2. “4.3.2 Hydraulic Control Banks” on page 86

Locating Pin to prop


side hoppers

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d. Fold down the left and right hopper sides by operating hydraulic control levers HC 2 “4.3.2
Hydraulic Control Banks” on page 86

HC 6

e. Remove the 4 bolts and Fold back the chute sides.

Note! Only applies to machines with the Hanging Screen Option fitted

4 bolts

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3.2 Additional Machine Preparation for Transport for Hanging Screen


Options

3.2.1 Raising the Recirculation Jack Legs


Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102
to raise the jack legs up fully by operating HC6. Refer to
“4.3.2 Hydraulic Control Banks” on page 86.

Jack Legs

3.2.2 Preparing the Midsize Transfer Conveyor

a. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. ..

Midsize transfer
conveyor

b. Slide IN the Midsize transfer conveyor by op erating HC8. Refer to “4.3.3


Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page
87.

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3.2.3 Preparing the Primary Screen Box

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to raise the angle of the primary screen to lift the weight off the locating pin on both sides, by
operating HC7. Refer to “4.3.2 Hydraulic Control Banks” on page 86.

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure pla tform remove the screen ox locating pins
and store these in a secure location.

c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102 to fully lower the angle of the primary screen to the bottom, by operating
HC7 Refer to “4.3.3 Hydraulic Control Banks with Hangi ng Screen [ QI441 HS ]
Option Fitted” on page 87.

Screenbox locating pin

4 Working Positons

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3.2.4 Preparing the secondary screen box

a. Raise the secondary screen box off the locating pins on both sides by operating HC7, refer to
“4.3.3 Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page 87.

Working Positon

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform remove the locating pins.

c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102 to raise the screen box up to the transport postion by operating
HC13

Locating pins Transport


Positon

d. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform Insert the locating pins. .

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3.2.5 Preparing the Fines Conveyor

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to raise th e the Fines Conveyor to t he transport position by opera ting HC7, refer to “4.3.3
Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page 87.

Transport
position

Transport Bar Locating Pin

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform assemble the transport bar insert the
locating pins f rom the transport postion. The transport bar and locating pins where
advised to be stored securely during installation.

3.2.6 Preparing the Stock pile Conveyor

a. Raise the Stock Pile conveyor slighty to take the weight off the locating pins, by operating
HC8 , the hydraulic lever for wire rope tension.

90° Pin
45° Pin
Location
Location

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b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Remove the locating pins of the transport bracket, slide out the
transport bracket and re insert the locating pins

Transport
Bracket

c. Remove the locating pin from the Stock Pile conveyor [ from the 90° or 45° position ]

d. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102. Lower the Stock Pile conveyor with the Hydraulic lever for wire rope tension by operating HC8,
until the conveyor is close to the horizontal JUST above the level of the transport bracket.

e. Rotate the Stock Pile conveyor until it is above the tranport bracket by operating HC8. Lower
the Stock Pile conveyor with the Hydraulic lever for wire rope tension by operating HC8 until the
conveyor rests on the transport bracket. Refer to “4.3.3 Hydraulic Control Banks with Hanging
Screen [ QI441 HS ] Option Fitted” on page 87.

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3.2.7 Positioning the Recirculation Conveyor into transport position

a. Remove the support bar and the two locating pins as shown.

remove bolts

Locating
pin

Feedboot extension
Support Bar plates

b. Fold down the feedboot extension plates

c. Assemble the support bar with the two locating pins under the recirculation conveyor

Locating pins

Support Bar

d. Refer to “5.2.2 Engine Start-up Seque nce” on pa ge 94 and slightly unfold up the
recirculation conveyor by operating HC 9 to lift the weight of the locating pin.

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Locating pin

e. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Remove the locating pin.

Working Position

f. Restart the engine, Refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102
and fold down th e recirculation conveyor by operating HC 9, and AT THE SAME TIME keep the
wire rope in tension by operating HC 9. Refe r to “4.3.3 Hydraulic Control Banks with Hanging
Screen [ QI441 HS ] Option Fitted” on page 87.

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g. When the transport position has been reached, Implement the Lockout and Tag
Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 40.

Transport
Position

h. Insert the locating pin when the hole is past the bottom of the support arm

Locating pin
past the supp ort
arm

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3.2.8 Preparing ladder 1 and ladder 2 for transport

a. To prepare Ladder 2 remove the lo cating pin from the ladder support bar which is in the
working position, swing the ladder inwards and insert the locating pin into into th e transport
postion.

b. Lossen the bolts and swing up the last 2 steps and secure with the bolts.

Loosen the bolts

Transport Postion

Ladder
Support
Bar

Working Postion

c. To prepare ladder 1, Lossen the bolts and raise up the the last 2 steps section, and then
tighten the bolts to secure.

Loosen the bolts Secure with


bolts

Ladder support

d. Remove the ladder support from the chassis and ladder and store in a secure location. Then
swing up the ladder up and through the two gates until the ladder rests on the platform.

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e. Securely fix the two gates to the ladder for transport.

3.2.9 Store the Loose Items

locating pins - 1 stock pile conveyor, 2 main coveyor, 2 for Fines Conveyor

-
locating pins - 2 screen box
natural fines - Hanging screen only
conveyor
Belt Troughs
Belt scraper - Midsize tra nsfer
conveyor - - Hanging screen only

Ladder 1 support

Located in Cont rol


Panel Cabinet
Impactor hammer tool

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3.2.10 Tracking the machine onto and off the transport vehicle

DANGER
CRUSH HAZARD
Moving machine can crush objects and personnel.
Before starting the machine visually check the machine and area around the
machine to make sure there is no one standing in the area.

Follow the Start Up Sequence for the tracking procedure


(refer to “5.2.5 Sequence For Tracking Machine” on page 97)

Note! engine idle rpm on engine start up is sufficient to track the machine onto or off the
transport vehicle. Any higher engine rpm is not recommended.

After tracking the machine onto the transport vehicle make sure all temporary sealing and transport
straps or chains are installed. DO NOT secure by tying down over the tracks. Lashing down is the
responsibility of the driver of the low loader.

Before tracking the machine off the transport vehicle make sure all temporary sealing and transport
straps or chains are removed.

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3.2.11
TRANSPORT

Due to our Design Department constantly seeking ways to improve


our products, we reserve the right to alter specifications at our descretion.

Overall width 3540mm [11' 8"]


Overall width ( RECIRC CONV ONLY ) 3300mm [10' 10"].

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Transport and Technical
Transport and Technical qi441

WORKING

OR
EY
NV
CO
TE
TA
RO
19059mm [62'-6"]

QI440

12925mm [42'-5"]

5357mm [17' 7"]

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3.2.12 QI441 Transport And Working Dimensions

TRANSPORT

TRANSPORT

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WORKING

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3.3 Technical Information

3.4 Technical Data and General Information

The QI441 is a Mobile Primary Impact Crusher constructed for high mobility and high output.

3.4.1 Feed Hopper

Nominal capacity 6 m³ (7.85yd³)

3 piece hydraulic folding wing plates

12mm thick reinforced

Wedge style retaining system

3.4.2 Primary Feeder

Hardox lined feeder 1278mm (4' 2") x 2365mm (7' 9")

Hydraulic drive variable speed 550 rpm to 1000 rpm

Twin eccentric shaft Oil lubrication

Amplitude Nominal 10mm (3/8")

3.4.3 Pre screen

Hardox top deck grizzly / punch plate 1360mm (4' 6") x 2160mm (7' 1")

Bottom deck mesh 1360mm (4' 6") x 1730mm (5' 8")

Single shaft hydraulic drive 990 rpm

Angle 10º decline

3.4.4 Impactor

Sandvik CI421 impact crusher

Feed opening 1360mm (54") x 800mm (31.5")

4 Bar rotor 1150mm (45¼") diameter

Rotor speed (variable) 502rpm to 620 rpm

Tip speed variable 30M/S(98Ft/S) to 37M/S (121Ft/S)

2 aprons Hydraulic assist

3.4.5 Main Conveyor

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Belt specification EP500 3 ply 8+2 grade X

Discharge height 4000mm (13' 1")

3.4.6 Natural Fines Conveyor

Belt specification EP400 3 ply 3+1.5mm

Belt width 650mm (25 ½")

Discharge height 3000mm (9' 10")

3.4.7 Power Unit

Engine Cat C13 Tier 3

Engine power 328 Kw (440 Hp)

Speed 1700 rpm to 2100 rpm

Fuel Tank 660 Litres (174 USG)

Hydraulic tank 660 Litres (174 USG)

3.4.8 Tracks

Length (centres) 4085mm

Track shoe width 500mm (19¾")

Tracking speed 1.4 kph (0.87 mph)

3.4.9 Hanging Screen Option Data

3.4.10 Recirculating Conveyor

Belt specification EP4003ply 3+1.5mm Chevron 15mm

Belt width 500mm (19 ¾")

Discharge height 4950mm (16' 3")

3.4.11 Fines Conveyor

Belt specification EP400 3 ply 3 + 1.5mm

Belt width 1200mm (47 ¼")

Discharge height 2850 mm (9' 4")

3.4.12 Stockpile Conveyor

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Belt specification EP4003ply 3+1.5mm Chevron 15mm

Belt width 500mm (19 ¾")

Discharge height 3070mm (10' 1")

3.4.13 Transfer Conveyor (Oversize and Midsize)

Belt specification EP400 3 ply 3 + 1.5mm

Belt width 500mm (19 ¾")

Discharge height N/A

3.4.14 Underpan feeder

Hardox lined stepped underpan 1022mm (40¼") x 2400mm (94½")

Speed 960 rpm

Amplitude 9mm (3/8")

3.4.15 Double Screen

Screen box 1 top deck 1426mm (5') x 1426mm (5')

Screen box 1 bottom deck 1426mm (5') x 1426mm (5')

Screen box 2 top deck 2440mm (8') x 1426mm (5')

Screen box 2 bottom deck 2440mm (8') x 1426mm (5')

Speed 1200 rpm

Amplitude 8mm (max)

3.5 General Technical Data


Operation Mode Transport Mode

Length: 16500mm [54’ 2”] 15730mm [51' 7”])

Width: 6830mm [22' 5"] inc side con 3000mm [9' 10"]

Height 4600mm [15’ 7”] 3600mm [11’ 10”]

Total weight Approximately 52500 KG ( 57.06 US ton /115743 Ibs)

Hanging Screen Option Fitted Operation Mode Transport Mode

Length: 19486mm [631 11”] 18450mm [60' 6])

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Width: 6830mm [22' 5"] inc side con 3540mm [11' 7"]

Height 11144mm [36’ 7”] side+stockpile 3760mm [12’ 4”]

Total weight Approximately 63200 KG (68.7 US ton / 139,040 Ibs)

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3.6 Options

3.6.1 Hopper extensions

3.6.2 Hopper Hardox liner plates back and sides

3.6.3 High impact Sandvik wear rubber back and sides

3.6.4 Central auto lube (crusher only)

3.6.5 Central auto lube

3.6.6 Remote Diesel pump

3.6.7 Water pump (Hyd)

3.6.8 Artic Packages


-20oC (-4oF) Artic Package

-30oC (-22oF) Artic Package

3.6.9 Tropical / High ambient package (may not be required)

3.6.10 Wheeled Dolly (Open circuit only)

3.6.11 Conveyor pull cords

3.6.12 Grizzly

3.6.13 Pre screen top deck punch plate

3.6.14 Pre screen top deck mesh (ashalt / secondary applications)

3.6.15 Pre screen open bottom rubber to feed natural fines conveyor (high fine /
sticky applications)

3.6.16 No overband magnet

3.6.17 No natural fines conveyor

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4.0 Product Overview

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4.1 Product Overview

This section has been designed to familiarise the user with the various controls and functions of the
individual components that make up the QI441

4.2 Major Components QI441


1
2 3 4 5

6 8
7

1. Main conveyor
2. Power Unit
3. Impactor
4. Pre Screen
5. Feed Hopper
6. Tracks
7. Natural Fines Conveyor
8. Primary Feeder
9. Underpan Feeder

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4.2.1 Hanging Screen [ QI441 HS ] Option

1 2
3

4
5
1. Recirculating conveyor
2. Main conveyor
3. Double screen
4. Fines conveyor
5. Stockpile conveyor

6. Oversize transfer conveyor


7. Midsize transfer conveyor

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4.3 Identification and Operation of the QI441 Controls


There are three sets of controls on the QI441:

1. The main control panel

2. Hydraulic control banks

3. The remote control which can be found in the control box upon delivery of the machine.

4.3.1 Main Control Panel

Control Panel
Emergency Stop

Emergency Stop
Reset Button

The main control panel consists of the following:

a. Ignition - This control is used to start and stop the machine

b. Emergency Stop, refer to “2 .6.1 Use of Emerg ency stop function” on pag e 37.
When pressed the engine will stop.

c. Display Panel- This pan el is used to o perate and observe the fu nctions of the
machine.

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Before starting up the machine ensure that all emerg ency stop buttons are not en abled on the
machine, handset or remot e if fitted. When the ig nition switch is turned to the on po sition, the
introductory display will appear. The operator must press the Emergency stop reset button when this display
appears. If the operators does not do this the machine must be turned off and on again.

All settings and procedures are accessed via the numbered buttons on this display panel.

To enter any command or access a new sub-menu display, simply press the relevant button.

To exit a particular sub-menu and go back one level, press the ESC button or a return button which
will be highlighted.

Active programs/options are identified to the user by a green symbol.

Function is OFF Function is ON

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4.3.2 Hydraulic Control Banks

HC 1 HC 2

HC1 No Function

HC1 Natural Fines Conveyor - Fold / Unfold

HC2 Wing Plates - Fold / Unfold, located under the feeder

HC 6

HC 5
HC3 HC4

HC3 Front Jack Legs - Raise and Lower

HC4 Impactor Hood - Open / Close)

HC5 Upper Curtain - Raise / Lower and Lower Curtain - Raise / Lower

HC6 Rear Jack Legs - Raise and Lower and Main Conveyor - Working Position / Transport Position

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4.3.3 Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted

HC 7
HC8
HC 7

HC7 Recirculating Jack Legs - Raise / Lower

HC7 Angle Screen

HC7 Raise Screen

HC7 Fold Fines Conveyor

HC8 Midsize transfer conveyor - Slide

HC8 Stockpile conveyor Rotate - Working Position / Transport Position

HC8 Stockpile conveyor Wire Rope Tension - Raise / Lower.

HC8 Stockpile Conveyor - Slide

HC9

HC9 No Function

HC9 Recirculation Conveyor - Fold / Unfold

HC9 Recirculation Conveyor Rotate- working Position / Transport Position

HC9 Recirculation Conveyor - Tension Wire

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4.3.4 Flow Control Valves with Hanging Screen [ QI441 HS ] Option Fitted

HC 7
FC2
FC 1

FC1 Overband Magnet Conveyor Speed adjust

FC2 Oversized Transfer Conveyor and Reciriculation Conveyor Speed adjust

FC2 Midsized Transfer conveyor and Stockpile Conveyor Speed adjust

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4.3.5 Radio Remote Control Unit

The radio remote control main function is to track the machine. Refer to “7.2.5 Radio Remote Control
battery Charging” on page 160 to keep the battery power charge level high at all times.

There are several controls on the remote unit:

• A joystick for each track (LH/RH) used to drive the tracks either forward or back. The diagram
below shows the direction of forward travel. The track joysticks control the track speed
proprtionally.

• An Engine Kill button that, if pressed will shut off the engine.

NOTICE DAMAGE TO MACHINE WILL RESULT IF MISUSED.

This switch should only be us ed in emergenc y situations. Machine will


require extensive preparation before a restart of the conveyors is possible as
material build may occur. Refer to “6.5.1 Start-up Sequence For Running the
Crusher” on page 133 for restart procedure.

• A On/Off toggle switch for the feeder for operator convenience.

• An on-off key switch (A) that is used to turn the remote unit on or off.

• A green push button (B) that must be pressed to activate the remote.

Engine Kill
Switch

A B

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4.3.6 Umbilical Remote Control Unit

The umbilical remote control has one function: to track the machine. Refer to “7.2.5 Radio Remote
Control battery Charging” on page 160 to keep the battery power charge level high at all times.

There are several controls on the remote unit:

• Auto Track Switch to automatically drive the tracks either forward or backwards at the
maximum speed [ speed depends on engine rpm ]. The machine will continously track until
this switch has been moved to the neutral position.

• Manual track buttons for each track (LH/RH) used to drive the tracks either forward or back.
These buttons will control the track speed proportionally but will only work when the Auto
Track Switch is in the neutral postion.

• An Engine Kill button that, if pressed will shut off the engine

The diagram below shows the direction of forward travel

Engine Kill
Switch

Manual Track
Buttons

AutoTrack
master Switch

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5.0 Commissioning and Shut Down

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5.1 Commissioning & Shutdown Safety

Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 13 of this
manual for addit ional information on safe operation, maintena nce and repa ir of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the
equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first
consulting all pertinent safety information.

5.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

5.1.2 Managing Work related Hazards with a Risk Assessment

You must a lways perform a local risk assessment before starting a task . This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

5.1.3 When carrying out maintenance or adjustment

Implement the Lockout and Tag Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40.

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5.2 Commissioning
Read And Follow All Instructions Concerning Set Up Of Your QI441. Failure To Do So
May Result In Damage To The Machine, May Result In Serious Injury Or Death, And May
Invalidate Manufacturer’s Warranties.

The Following Instructions Assume Transport Of The QI441 From A Lo w Loader-type


Vehicle In Close Proximity To The Job Site; If The Machine Is Transported In A Different
Manner, Contact The Manufacturer For Additional Set Up Instructions.

It is recommended that set up of the QI441 be carried out by a representative of Sandvik


Mining and Construction Mobile Crushers and Screens Ltd. or by trained and authorised
representative of the dealer.

5.2.1 Preparation for Machine STARTUP

SURFACE PREPARATION:

The QI441 is designe d for opera tion on a solid, level surfa ce. It is importa nt that the machine is
placed on so lid ground that must be capable of carr ying the weight of the machine and that the
machine is placed on level ground. The machine should be level to within 2 degrees from left to right.
An appropriate site must be identified prior to delivery and unloading of the machine.

VISUAL INSPECTION:

Before powering up the engine a visual inspection of the QI441 should be performed.
Inspection should ensure that:
1. All safety equipment is installed and functioning properly.
2. Any loose items delivered with the QI441 have been secured or removed from the
machine.

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5.2.2 Engine Start-up Sequence


a. Ensure all Emergency Stops are released and that the engine kill switch on the remote control
is also turned off. Refer to “2.6.1 Use of Emergency stop function” on page 37.

b. Turn on the ignition switch (but do not start the engine) and check the following displays are
shown respectively (Fig. 5.1). It should take a few seconds. If there is a problem it will be shown on
the display.

c. Press the blue Emergency Stop Reset button which will be illuminated to reset the emergency
stop system. The emergency stop system can only be reset when the splash display is shown.

( Fig. 5.1 ) Splash Display


Emergency Stop Reset Button

d. If the emergegency stop system is not reset the display below will have a warning me ssage.
The ignition switrch must be turned off and steps a) to c) repeated.

e. Now start the machine, turn the ignition switch fully clockwise. The siren will sound and the
beacon will flash for 10 seconds before the engine will start. (If engine turns and does not start,
turn off the ignition and wait for a few seconds, then try and start again.)

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5.2.3 Setting Language of Control Panel Display.

Software version

Control Panel Serial Number

Button 3

From the Main menu display (Fig 5.1.) press and hold the ESC button for 10 seconds to access the
information page.

Press Button 3 to select the language required. The country flag or a greeting will appear). To return
to main menu press ESC.

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5.2.4 Setting the date/time

From the Main Menu page, press Esc and hold for 10 seconds.

• Hold and press button 8 until the value you wish to edit changes to red.

• The “Hours” field will be highlighted first and begin to flash. To increase the hours
press the Up arrow button. To decrease the hours press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “minutes” field will begin to flash. To increase the minutes press the Up arrow
button. To decrease the minutes press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “seconds” field will begin to flash. To increase the seconds press the Up
arrow button. To decrease the seconds press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “Days” field will begin to flash.To increase the Days press the Up arrow
button. To decrease the Days press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “Months” field will begin to flash. To increase the Months press the Up arrow
button. To decrease the Months press the Down arrow button.

• Press the right arrow button to move to the next field.

• The “Years” field will begin to flash.To increase theYears press the Up arrow
button. To decrease the Years press the Down arrow button.

• Finally press the right arrow button to store the new date/time. The red highlighted
option will disappear from the date/time fields.

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5.2.5 Sequence For Tracking Machine

DANGER
CRUSH HAZARD
Moving machine can crush objects and personell.
Before moving the machine visually check the area around the machine to
make sure there is no one standing in the vicinity.

The operator must be fully trained in the operation of this equipment. When tracking, the operator
must be in a position to have an all round view of the operation. A additional supervisor should assist
where this is not possible. Make sure the site is clear of non essential persons. Erect barriers around
the area and post warning signs where site conditions warrant this. Make sure the tracking alarm
makes a clear sound.

This equipment must never be tracked on gradients that are more than:

10 degrees side tilt OR 20 degrees front tilt

a. Start the engine if required. Refer to “5.2.2 Engine Start-up Sequence” on page 94

b. Switch on the tracking mode by pushing button 2 as shown (Fig. 5.2).

( Fig. 5.2 )

c. When tracking has been selected the main conveyor will rise automatically.

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d. The display as shown (Fig. 5.3) will appear.

Button 1
Manual Handset Activate

Button 2
Radio Receiver Activate
Engine RPM
Radio Receiver Signal Lower / Raise
Strength Indication
Radio Receiver Activate
(Fig. 5.3)

e. For Umbilical remote control, connect the umbilical lead to the control panel and press the
switch on the unit as shown next. Then press button 1 (Fig. 5.3), the siren and beacons will sound
and flash for 10 seconds. During the 10 seconds a yellow halo will appear around button 1 icon.

Switch

f. After the 10 seconds the button 1 icon will then have a green halo. Tracking will now be active
with the proportional controls on the umbilical control unit.

g. To disable tracking press button 1 again and the green halo around the icon will disappear.

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h. For Radio remote control press button 2 (shown in Fig. 5.3). The yellow halo will not appear
until signal strength is good and the remote is turned on.

i. Turn the transmitter to the On ‘I’ an d wait for the green light to flash consistently after a few
seconds as shown below (Fig. 5.4)

Remote Wait for


Control Green
on “1” Light to
flash

(Fig. 5.4)

j. The Icon on button 2 will now have a yellow Halo. A green icon on the display shown in Fig.
5.3 will now be flashing to remind you to press the green activate remote button in Fig. 5.5.

k. Activate the radio transmitter by pushing the green button on the unit as shown below (Fig.
5.5). The siren will sound & bea con flash. It will take 10 seconds before the radio transmitter is
ready to use.

Activate Remote

(Fig. 5.5)
Transmitter signal strength

l. The icon will change to a green halo. Radio tracking is now available.

m. To disable tracking simply press button 2 and the halo will disappear (shown in Fig. 5.2).

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5.3 Initial Setup and Operation

WARNING
Before attempting to set-up the machine ensure that the operator has read and
fully understood this and all the preceeding sections in the manual.

DANGER
Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

5.3.1 Remove the Loose Items


locating pins - 1 stock pile conveyor, 2 main coveyor, 2 for Fines Conveyor

locating pins - 2 sc reen box -


Natural Fines
Hanging screen only
Conveyor
Belt Troughs
Belt scraper - Midsize transfer
conveyor - Hanging screen only
Ladder 1 support

Located in Cont rol


Panel Cabinet
Impactor hammer tool

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5.3.2 Set Up ladder 1 and ladder 2

a. To set up ladder 1 from the transport position, attach the ladder support to the chassis and
remove the secure fixings which holds the ladder and the two swing doors together. Secure the
ladder support to the chassis and then swing the ladder down and secure with bolts to the ladder
support.

Secure with bolts

Ladder support

b. Lossen the bolts and lower of the the last 2 steps section, and then tighten the bolts to secure.

Secure with bolts

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c. To set up Ladder 2 from the transport position, lossen the bolts and swing down the last 2
steps and secure with the bolts. .
Secure with bolts

Transport Postion

Ladder
Support
Bar

Working Postion

d. Remove the locating pin from the ladder support bar which is in the transport position, swing
the ladder outwards and insert the locating pin into into the working postion.

5.3.3 Procedure to engage Auxiliary Controls


a. Restart the engine, Refer to “5.2.2 Engine Start-up Sequence” on page 94 and go to the
main menu and press button 4 (fig 5.6) to activate Auxiliary function. The siren will sound
continously when in this menu mode. .

Button 4
Auxiliary Function
(Fig 5.6)
(Fig 5 6)
b. Wait 10 seconds for the controls to be activated, then the green shadow will appear around
symboll.

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5.3.4 Folding the hopper sides

a. Fold out the chute sides and bolt up the chute side in the four holes.

Note! Only applies to machines with the Hanging Screen Option fitted.

4 bolts

b. Fold up the left and right hopper sides by operating hydraulic control levers HC 2

HC 2

c. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Using a secure platform if needed, an additional supervisor
is required to guide the side hopper props to re st on the support plate. Insert locating
pins to prop the sides (1 each side) securely in position (see picture below ) .

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Locating Pin to prop


side hoppers

d. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 . to fold up the hopper rear by operating hydraulic control levers HC2.

e. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40 . Using a secure platform if needed, an additional supervisor
can insert the two wedges (as shown in the picture below) to secure the rear hopper in
place.

f. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102. Lower the left and right hopp per sides until their weight is resting on the
props (refer to above) by operating hydraulic control levers HC2 .

Insert the
Wedges

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5.3.5 Unfold the Natural Fines Conveyor and fitting the belt troughs

a. Remove the two locating pins holding the rachet torque arm. If necessary adjust the torque
arm length to allow the locating pins to be removed.

Locating
pins

b. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to unfold the Natural Fines Conveyor by operating hydraulic control lever HC1.

HC2

Slide stop top


locating pin position

c. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

d. Remove locating pin from slide sto p at the bottom and relocate the slide stop to
the top postion and re-insert locating pins.

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e. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102) to lower the Natural Fines Conveyor onto the slide stop, b y operating the h ydraulic control
lever HC1.

f. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. . Attach the Belt troughs to the mid section of the Natural
Fines Conveyor.

Attach this
item first

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5.3.6 Unfolding the main conveyor and Positioning into Working Position

a.Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102)
to unfold the main conveyor, operating hydraulic con trol HC6 ref er to “4.3.2 Hydraulic Control
Banks” on page 86

b.Implement the Lockout and Tag Proce dure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

c. Attach the ladder [supplied] into the l adder fix p oint or use a secure platform to
insert the locating pin each side. Remove the ladder

Locating Pin

Ladder fix
Point

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5.4 Additional Initial Setup and Operation for Hanging Screen Options

5.4.1 Setting Up the Recirculation Conveyor

a. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Remove the two locating pins

Locating pin

b. Restart the engine, Refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102
and unfold up the recirculation conveyor by operating HC 9, and AT THE SAME TIME keep the wire
rope in tension by operating HC 9. Refer to “4.3.2 Hydraulic Control Banks” on page 86.

Working Position

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c. When the working postion has been reached. Implement the Lockout and Tag
Procedure, refer to “2.6.4 Isolation and energy dissipation” on page 40.

d. Inspect the location ofthe locating pin. If the hole is not aligned restart the engine,
Refer to “5.2.2 Engine Start-up Sequence” on page 94 and unfold up the recirculation
conveyor by operating HC 1 to raise the recirculation conveyor slighty until the holes are
aligned.

e. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Insert the locating pin.

Locating pin

f. Remove the two locatin g pins of the suppo rt bar which is located und er the recirculat ion
conveyor in the transport mode. Remove the support bar.

Locating pins

Support Bar

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g. Fold up the feedboot extension plates and bolt together

bolt plates together

Locating
pin

Feedboot extension
Support Bar
plates

h. Attach the support bar with the two locating pins as shown.

5.4.2 Preparing the Stock pile Conveyor

Transport
Bracket

Hydraulic
lever

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102. Raise the Stock Pile conveyor with the Hydraulic lever for wire rope tension by operating
HC8, until the conveyor is JUST clear of the transport bracket.

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b. Rotate the Stock Pile conveyor to the desired working position by operating HC8. You can
choose between a 45° and a 90° angle.

90° Pin 45° Pin


Location Location

c. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Insert the locating Pins, Qty 2

d. Raise the Stock Pile conveyor by opearting HC8 , the hydraulic lever for wire rope
tension - RAISE lever, until the conveyor is at full working height.

e. Remove the locating pins of the transport bracket, slide in the transport bracket and re insert
the locating pins

Transport
Bracket

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5.4.3 Unfolding the main conveyor and Positioning into Working Position

a.Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102)
to unfold the main conveyor, operating hydraulic con trol HC6 ref er to “4.3.2 Hydraulic Control
Banks” on page 86

b.Implement the Lockout and Tag Proce dure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

c. Attach the ladder [supplied] into the l adder fix p oint or use a secure platform to
insert the locating pin each side. Remove the ladder

Locating Pin

Ladder fix
Point

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5.4.4 Preparing the Fines Conveyor

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to raise the weight off the locating pins of the Fines Conveyor by operating HC7, refer to “4.3.3
Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page 87.

b. Remove the locating pins and th e tranport bar of the Fines Conveyor and store in a safe
location away from the machne, and lower the Fines Conveyor fully by operating HC7.

Transport Bar
Locating Pin

5.4.5 Preparing the secondary screen box

a. Lift the weight off the locating pins on both sides by operating HC7, “4.3.2 Hydraulic Control
Banks” on page 86

b. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Using a secure platform remove the locating pins from the
transport postion.

Locating pins Transport


Positon

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c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to raise the screen box up to the working postion required by operating HC7.

Working Positon

(Fig. 5.4)

d. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Using a secu re platform insert the screen box locating pins
into the working position required.

Note! Using working position A (shown in Fig 5.4) positions the secondary screenbox at the
highest angle, which increases the speed of the material. However, then the primary
feeder can only be set at two working positions, refer to “5.4.6 Preparing the primary
Screen Box” on page 115.

Note! Using working position B (shown in Fig 5.4) positions the secondary screenbox at the
lowest angle, which lowers the speed of the material. The primary feeder can then be
set at four working positions, refer to “5.4.6 Preparing the primary Screen Box” on page
115.

Working Positon

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5.4.6 Preparing the primary Screen Box

a. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page
102 to raise the angle of the primary screen to a working position by operating HC7 . Refer to “4.3.3
Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page 87. Make
sure the screen box is higher than the desired hole location, refer to “6.5.11 Primary Screen Box
Working Angles” on page 145.

b. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Using a secure platform insert the screen boxscreen box
locating pins into the working position required. Refer to “5.4.5 Preparing the secondary
screen box” on page 113.

Screenbox locating pin

A
B

c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102 to
lower the primary screen box onto the top of the screen box locating pins by operating HC7 .

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5.4.7 Preparing the Midsize transfer conveyor

a. Slide OUT the Midsize transfer conveyor by operating HC8

b. Implement the Lockout and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. .

Midsize transfer
conveyor

5.4.8 Preparing the Recirculation Jack Legs

Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls” on page 102 to
Lower the jack legs until the weight of the Recirculation Unit acting on the ground reaches a preset
hydraulic pressure by operating HC7.

Jack Legs

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5.4.9 Belt Tension

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

Torque Arm

Locknuts

Replacing Belt
1. Open flywheel guards.
2. Slacken the belt by loosening the locknuts on the torque arm.
3. Remove old belt and place the new belt around the pulleys, taking up slack
with the torque arm, and tightening the locknuts.
4. Close flywheel guards
5. Run the impactor in maintenance mode for 1 - 2 minutes, at low engine
speed (rpm) (refer to “5 .2.2 Engine Start-up Sequ ence” on page 94)(refer
to “6.7 Manual Operating Mode” on page 121.
6. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
7. Wait for pulleys to stop rotating

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8. Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

9. Open flywheel guards


10. Mark the belt on the tight side main span at two points, 1000mm apart.
Tension the belt until the distance between the marks has increased by the
value 5.6mm.
11. Tighten the locknuts on the torque arm
12. Close flywheel guards
13. Run the impactor, at lo w engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
14. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
15. Wait for pulleys to stop rotating
16. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40

17. Open flywheel guards


18. Remeasure between the two marked points on the belt
19. Adjust belt accordingly (refer to “Adjusting the Belt” below)
20. Tighten the locknuts on the torque arm
21. Close the guards

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Adjusting the Belt

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

1. Open flywheel guards.


2. Take-up slack with the torque arm, and tighten the locknuts.
3. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
4. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
5. Wait for pulleys to stop
6. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40

7. Open flywheel guards.


8. Mark the belt on the tight side main span at two points, 1000mm apart.
Tension the belt until the distance between the marks has increased by the
value 4.4mm
9. Tighten the locknuts on the torque arm
10. Close flywheel guards
11. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
12. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
13. Wait for pulleys to stop
14. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40

15. Open flywheel guards.


16. Remeasure between the two marked points on the belt
17. Adjust belt accordingly.
18. Tighten the locknuts on the torque arm
19. Close the guards

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5.5 Machine operation

Refer to “ 6.0 Operation” on page 127

5.6 Machine Shut Down

It is recommended to operate the QI441 until all material has been removed from the feeder and
crusher chamber and that the conveyors are not producing a stock pile.
Manual Stop Sequence

Button 1 Button 5

Button 2

Button 3

Button 4

Back Arrow
When Stopping the machine manually the operations can only be stopped in the correct sequence

1. The feeder is shutdown by pressing Button 5.


2. Once the feeder has completely stopped the side conveyor can be shutdown by
pressing button 3.
3. Once the side conveyor has completely stopped the pre screen can be shutdown
by pressing button 2.
4. Once the pre screen has completely stopped use the back arrow to navigate to the
Run Mode Display.
5. The main conveyor can now be shutdown using button 3.
6. Once the main conveyor has completely stopped the pan feeder can be shutdown
by pressing button 2.
7. Once the main conveyor has completely stopped the crusher can be shutdown by
pressing button 1. Within a preset time the crusher will stop.

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WARNING
FLYING MATERIAL HAZARD
There Is Risk Of Serious Injury Or Death Due To Rejected Material.
Keep away from the Feeder area and the conveyor belts areas, only full trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

CRUSH HAZARD
There is Risk of Serious Injury or Death due to Other Heavy Machinery Working
In The Area.
Keep away from the Feeder area and the conveyor belts areas, only fully
trained and authorised operators in loading the machine and collecting
processed material should be in this area.

5.6.1 Auto Stop Sequence

Button 5

(Fig. 5.7)

1. Navigate to the Auto Start Stop menu display. By pressing button 1 on the main
menu display (see Fig. 5.6)
2. Press button 5 to stop, Fig 5.7
3. The machine will stop the functions of the machine in the correct sequence.
4. Within a preset time the crusher will stop, the engine will ramp down and the main
conveyor will stop.

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WARNING
FLYING MATERIAL HAZARD
There Is Risk Of Serious Injury Or Death Due To Rejected Material.
Keep away from the Feeder area and the conveyor belts areas, only full trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

CRUSH HAZARD
There is Risk of Serious Injury or Death due to Other Heavy Machinery Working
In The Area.
Keep away from the Feeder area and the conveyor belts areas, only full trained
and authorised operators in loading the machine and collecting processed
material should be in this area.

It is recommend to operate the QI441 until all ma terial has bee n removed from the feeder and
crusher chamber and that the conveyors are not producing a stock pile.

Refer to “6.6 Clearing Crusher Chamber Jam’s” on page 147

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5.6.2 Preparing the machine for transport or for the machine to be moved to
another location

Follow the instructions in “3.1.2 Machine Preparation for Transport” on page 54

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5.6.3 Emergency Stop

In the event of an accident or any serious problem with the machine you should press the nearest
emergency stop button, refer to “2.6.1 Use of Emergency stop function” on page 37.

EMERGENCY STOP:

a. Engage the nearest emergency stop, the location of which can be found in the
safety section.

b.Switch off the engine and remove the ignition key.

c. Implement the lo ckout and tag pro cedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

d. Only when the machine is fully switched off, should an attempt be made to solve the problem.

RESTART AFTER EMERGENCY STOP:

a. Ensure that the problem has been solved

b. Ensure that all personnel are clear of the machine.

c. Ensure that all safety devices are correctly fitted and fully functional.

d. Release all emergency stops.

e. Re-start the engine in accordance with the correct procedure, refer to “5.2.2 Engine Start-up
Sequence” on page 94.

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5.7 Location Of Emergency Stops On QI441

There are six Emergency Stops on the QI441 and one Engine Kill Switch on the remote control.

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Control Panel
Emergency Stop

Emergency Stop-
Reset Button

Engine Kill Switch

Umbilical Tracking
Lead Engine Kill
Switch

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6.0 Operation

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Operation qi441

6.1 Operation Safety


Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 13 of this
manual for additional information on safe operation, maintenance and repair of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on
the equipment or making any adjustments. Do not attempt operation, maintenance or repair with out
first consulting all pertinent safety information.

6.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

6.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going to
be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk).

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

6.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

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6.2 Loading the feeder


Loading the mobile unit correctly is essential in order to achieve adequate material delivery to the
crushing chamber. This is extra important when loading large stones.

6.2.1 Avoid damage to equipment


Never use the bucket to force too large material into the crusher.
NOTICE
Never drop the material from height into the feeder.
Accidental contact between bucket and feeder may cause vibrations that
can damage the feeder.
Never load on the “grizzly” section in the feeder. Ref to fig 1.
Never load directly into the crusher.

• Always lower the bucket close to the feeder when loading.

• Always load at regular intervals. Always fill up the feeder before it is empty.

• Load mixed sized materials.

• Try to keep the crusher full at all times.

• Adjust the feeder speed if necessary.

• Avoid interruptions, load material at a steady flow.

• Remove the stockpile of crushed material before it reaches discharge conveyor

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WRONG! too Far into feeder WRONG! Too High UP

Fig 1

WRONG! Bucket in contact with feeder CORRECT!


Load from side

WARNING
FLYING MATERIAL HAZARD
Risk of damage to the machine loading the feeder or personnel Injury of the driver.
It may be possible for the impactor to eject material to the rear of the qi441.

It is recommended to load the feeder from the sides only

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6.3 Common Applications


The QI441 may not be modified for use in non-aggregate sorting applications.
unauthorised modification of the machine, or use of the QI441 in applications
other than indicated applications, will void all warranties provided by the
manufacturer. the manufacturer assumes no responsibility for damage to the
QI441, or for personal injuries, resulting from use of the QI441 in unauthorised
applications. Risks associated with misuse of the QI441 rest exclusively with the
end user.

6.3.1 Construction, Demolition and recycling

• Concrete / Rebar

• Asphalt

• Bricks

6.3.2 Minerals and Quarrying

• Granite

• Limestone

• Sandstone

• Slate

6.3.3 Maximum Feed size for Crusher

Maximum feed size for crusher = 600mm. Feed size larger than 600mm could
NOTICE either jam in the crushing chamber and or cause major feed spillage from
the feeder. Refer to “6.4 Feed and Jams” on page 132.

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6.4 Feed and Jams

WARNING!
Never Feed combustible processing material into the impactor when the impactor
chamber is empty, avoid feeding solitary round rocks

Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be
thrown up at high speed from the impactor chamber

Explosives
Never remove blocking boulders from the impactor by blasting.
Blasting may cause personal injury and seriously damage bearings or other parts.
Sandvik takes no responsibility for damage to personnel or to the equipment when
blasting is used.

CI421 HSI crushers must never be “choke” fed.


It is essential the feed material is fed gradually and evenly across the complete width of
the feed hopper / opening

Risk of crushing
Never stand inside the impactor when it is blocked or jammed, even if the machine has
been stopped. You may be pulled sharply downwards together with the material in the
crushing chamber and crushed.

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6.5 Operating the QI441


Before Commencing general operation it is recommended that the following checks are carried out.

• ENGINE OIL LEVEL (refer to engine manual)

• HYDRAULIC OIL LEVEL (“7.3.1 Hydraulic Oil daily check” on page 167)“7.6.8
Hydraulic Oil Requirements for HPTO Clutch” on page 189

• DIESEL LEVEL (“7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank”
on page 164)

• NORMAL DAILY CHECKS (“7.2 Maintenance Schedule” on page 151)

• VISUAL INSPECTION:

1. Ensure that there are no loose bolts and no loose guards and
2. All safety devices such as EMERGENCY STOPS (“2.6.1 Use of Emergency
stop function” on page 37) are fully functional
3. Inspect the machine at least once per shif t for damaged or def ective
components. If any damage is observed, or if the machine exhibits any
malfunction or other unexpected operation, notify management and your
maintenance department immediately.

6.5.1 Start-up Sequence For Running the Crusher

You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going
to be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

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a. Make sure all Emergency Stops (“2.6.1 Use of Emergency stop function” on page 37) are
released and that the Engine kill switch on the remote control is also turned off.

b. Turn on the ignition switch (but do not start the engine) and check the following displays are
shown respectively (Fig. 4.7). It should take a few seconds. If there is a problem it will be
shown on the display.

(Fig 6.5)

c. If the emergegency stop system is not reset the display below will have a warning me ssage.
The ignition switrch must be turned off and steps a) to c) repeated.

d. Now start the machine, turn the ignition switch fully clockwise. The siren will sound and the
beacon will flash for 10 seconds before the engine will start. (If engine turns and does not
start, turn off the ignition and wait for a few seconds, then try and start again.)

Button 1 - Auto Mode


Button 2 - Tracks Mode
Button 3 - Fault Log
Button 4 - Customer Parameters
Button 5 - Engine Readings
Button 6 - Maintenance & Service Mode
Button 7 - Open Impactor / DC Motor

Fuel Level is also shown on footer as a percentage.

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6.5.2 Auto Run Mode

Select Auto Run by pressing button 1 on the Crusher Run Menu display as shown below. Selecting
this option allows the software to utilise pre-determined settings to operate the machine. The auto
run display will appear as shown below.

button 1

button 1

Crusher Auto Run


Mode start up

To start automatic Run mode PRESS BUTTON 1

The engine will ramp to clutch engagement speed. Once the speed is eached, a 10 second warning
will sound and the clutch will start to engage; when the control system has detected the clutch has
engaged the engine will then ramp to the operating speed.
After the Engine has reached the operating speed the main conveyor will start after a 10 second
warning, then the display will automatically switch to Feeder Control display (Fig. 6.6) . This display
enables the operator to select the pre-screen (button 2) and side conveyor (button 3), once the
pre-screen is started the Feeder icon (button 5) will flash to indicate to the operator that the Feed

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Operation qi441

Conveyor is now available to start.

button 5

button 2

button 3

(Fig 6.6)

The qi441 will now be runinng in Automatic Run Mode, the following adjustments can be made
however the operator must perform the following tasks before adjusting the Automatic run mode.

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.)

Button 1 - Auto Stop


Button 2 - Pre-Screen Start/Stop (10 second pre-start warning)
Button 3 - Side Conveyor Start/Stop (10 second pre-start warning)
Button 4 - Radio Control On/Off for the Feeder
Button 5 - Feeder Start/Stop (10 second pre-start warning)
Button 6 & 7 - Feeder Speed adjustment
Button 8 - Engine Speed adjustment (adjust engine speed with crusher speed feedback)

When button 5 (Feeder Start/Stop) is pressed the icon will flash. Machine sirens will sound and the
beacons will flash for 10 seconds, when time has expired the feeder conveyor will start.

To stop the crusher in Auto Mode -


Press button 1 to begin the Auto Stop sequence.
The Feed conve yor will stop, followed by the Pre-s creen, side conv eyor (if enabled),
Panfeeder and main conveyor. The engine will then ramp to a set engine speed and the clutch
will disengage. During this shutdown sequence there will be intermittent beeping to indicate
that the plant is shutting down.

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6.5.3 Automatic Mode - Recirculation System


Press button 1 on the main menu as shown below.

button 1

button 1

Crusher Auto Run


Mode start up

Note! The Recirculation option must be enabled in the parameters before starting the
machine.

To start automatic Run mode PRESS BUTTON 1

The engine will ramp to clutch engagement speed. Once the speed is eached, a 10 second warning
will sound and the clutch will start to engage; when the control system has detected the clutch has
engaged the engine will then ramp to the operating speed.

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6.5.4 MMPRO S menu Flow chart in automatic Run mode

Button1 Main
Menu

Escape
Escape Escape Escape Escape

AutoStart Feeder Feeder Unblocking Information


Stop Control Parameter Screen Screen
Screen Screen

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6.5.5 Manual Run Mode

Manual run gives the operator manual control of startup and shutdown of the machine, but will only
allow the functions to be switched on or off in the correct sequence. To access the run mode display
press button 1 on the main menu display. The operator can now access the Manual Mode Menu by
pressing Button 2.

(Fig 6.7)

button 1

Manual Run Mode


Button 2

Manual Mode Menu

button 1

button 2

button 3

Back to Run Mode display Forward to


Feeder Control
display
Button 1 - Crusher Start/Stop
Button 2 - Pan-Feeder Start/Stop
Button 3 - Main Conveyor Start

Button 1 icon will be flashing to highlight to the operator that the crusher start function is available.
Once selected the engine will automatically go to the present clutch engagement speed,and as
soon as this speed is achieved there will be a 10 second warning before enabling the clutch.

Note! Engine speed can not be adjusted when the crusher is in this mode of operation.

When the system has detected that the crusher is engaged, the operator can then continue with the

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manual start up sequence.

Engine speed buttons will appear giving the operator the option to increase the engine speed and at
the same time Button 2 will flash highlighting to the operator that the pre-screen function is available
to start. When button 2 is pressed a 10 second warning will sound and then the pre-screen will start.

Once the pre-screen has started, Button 3 will then flash indicating to the operator that the Main
Conveyor is ready to be enabled - once selected the 10 second warning will sound until the Main
Conveyor starts.

As soon as the Main Conveyor is running and the engine is above minimum speed the menu display
will automatically switch to the feeder control display.

6.5.6 Feeder Load Control


The Feeder Parameter display can accessed from the Feeder Control display by using the left and
right buttons.

Feeder Control display

Select right arrow (3) on


Feeder Control display

Feeder Parameter display

(Fig 6.8)
Button 1 & 2 - Feeder High Load - Set the value for the feeder kick down value.
Button 3 - Enable feeder load control system
Button 4 - Sandvik Service Parameter Adjust (Code required)
Button 5 & 6 - Feeder Low Load - Set the value for the feeder kick up value
Button 8 - Customer Service Parameter Adjust

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Feeder Load control On/Off (Button 3):


When the operator selects this function the control system will regulate the feeder speed in relation
with engine load. The load settings can be adjusted by pressing buttons 1 - 2, increasing the load
control value and buttons 5 - 6, decreasing the load control value. When the load control is on, the
icon will be highlighted in green.

6.5.7 Machine Adjustment

Feeder Parameter display

Select right arrow (4) on Feeder


Parameter display to access
Machine Adjustment display

Machine Adjustment display

(Fig 6.9)

Button 1 - Open Crusher Inlet


Button 2 - Close Crusher Inlet
Button 3 - Open Apron (only available when the feed conveyor is off)
Button 4 - Close Apron (only available when the feed conveyor is off)
Button 5 - Conveyor Raise (Not available while the machine is in run mode)
Button 6 - Conveyor Lower (Not available while the machine is in run mode)
Button 7 - Engine Values

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6.5.8 Tail Level adjustment

Machine Adjustment display

(Fig 6.10)

Select right arrow (5) on


Machine Adjustment display to
access Tail Level Adjustment
display

Tail Level Adjustment display

Material level at
tail conveyor
Function
disabled

Decrease Set
Point
Feed conveyor
automatic
Increase Set restart
Point

Button 3 & 4 will adjust the set point at which the conveyor will stop running when material has
reached a certain height from the end of the conveyor.

Note! If the level is set to 200mm, it will disable the function and “OFF” will be displayed on
the display.

When button 8 is pressed and the arrows around the icon are green, this will allow the feed
conveyor to automatically restart if the material at the level sensor drops below the set point.
If arrows around the icon are red, the feed conveyor needs to be manually restarted from the
control panel.

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6.5.9 Are Precautions Adequate?

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.)

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

Turn the radio Transmitter to the ON ‘I’ position.

“I”

Green button

Press the green button on the transmitter and activate the receiver.

Move the toggle switch in the centre of the transmitter.

Toggling the button to the left will switch the feeder Off and On as required.

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6.5.10 Diverter Chute

The feeder section of the QI441 will separate the smaller sized material away from the material to be
crushed. The operator has a choice as to how the QI441 will stockpile this graded material with the
use of the Diverter Chute and Natural Fines Conveyor.

Diverter Chute Handle

Position 1

Position 2

Position 3

When changing the position of the Diverter Chute ALWAYS -

• Implement the Lockout and Tag procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

• Make sure that the locking pin on the Diverter chute handle is securely attached.

Postion 1 - All graded material is directed onto the Natural Fines Conveyor to be stock piled
separately away from the main conveyor stock pile.

Postion 2 - 50% of the graded material is mixed with the crushed material from the impactor
travelling on the main conveyor to be stock piled together.

Postion 3 - 100% of the graded material is mixed with the crushed material from the impactor
travelling on the main conveyor to be stock piled together.

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6.5.11 Primary Screen Box Working Angles

Screenbox locating pin

3 Working Positons

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6.5.12 Fault Logs

To access fault logs, select button 3 on the main menu.


(if required access the main menu by pressing the ESC (Escape) button

This section shows details of faults such as fault number: “xx”, time and date the fault occurred while
the system was running.

This system records the last 25 faults reported to the machine and the operator is able to scroll
through the fault logs by using the Up/Down buttons whilst in this mode.

Faults are automatically highlighted to the operator on the main menu display when they occur with
a clear description of the fault so the operator can take action.

To clear the fault message from the display the user must confirm that action has been taken and
they can reset the display by pressing the OK button. If the fault is not cleared then the warning will
reappear and another entry is recorded in the log.

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6.6 Clearing Crusher Chamber Jam’s

6.6.1 Managing Work Related Hazards with a Risk Assessment


You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going to
be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

Button1 Main
Menu

Escape
Escape Escape Escape Escape

AutoStart Feeder Feeder Unblocking Information


Stop Control Parameter Screen Screen
Screen Screen

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Navigate to the unblocking display. Refer to “6.5.7 Machine Adjustment” on page 141

Press button 1 to Open Impactor Inlet Chute

Press button 2 to Close Impactor Inlet Chute

If the above steps do not clear the blockage contact Sandvik.

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7.0 Maintenance

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7.1 Maintenance Safety


Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 13 of this
manual for addit ional information on safe operation, maintena nce and repa ir of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on the
equipment or making any adjustments. Do not attempt operation, maintenance or repair with out first
consulting all pertinent safety information.

7.1.1 Who is at Risk

• Operators, Maintenance Personnel,


• Subcontractors and anybody else in the vicinity of the machine

7.1.2 Managing Work related Hazards with a Risk Assessment

You must always pe rform a local risk assessment before s tarting a ta sk. This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the environment,
your equipment and/or work method while you are performing the task.

• Assess the hazards to determine what scale of control is required, apply controls to
manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

7.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40.

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7.2 Maintenance Schedule


Only Trained and Autho rised Personnel are a llowed to carry out maintena nce. For
maintenance schedules and procedures relating to Original Equipment manufacturers,
refer to “ 11.0 OEM Section” on page 351.

Months 2000 hrs


Every 6 Months
Every 3 Months

When Needed
Every 250 Hrs

Every 12
1000 Hrs
Weekly

500 Hrs
Daily
POWERUNIT - Engine
After First 50 Hours Carry Out Full Service on
Engine and Hydraulic System
Engine Oil Level - Check 
Engine Oil & Filter - Change 
Engine Coolant Level - Check 
Engine Air Filter and Pre-Cleaner - Check * 
Air Filter Element - Change (More Frequent If 
Required) Change Safety Cartridge Every 3rd
Time *
Fuel Water Trap System - Drain * 
Engine Fuel Filters - Change (More Frequent If 
Required)
Battery Fluid Level and Terminal - Check 
See Engine Manual for Other Maintenance 
POWERUNIT - Hydraulics
Hydraulic Oil - Check Level 
Hydraulic Tank Breather- Check/Change *  
Hydraulic Oil - Check Temperature (Max 70oC) 
Hydraulic Oil Condition Test - Check 
Hydraulic Oil – Replace (Or As Needed)  
Hydraulic Hoses and Component - Check 
Hydraulic Return Line Filter - Change 

* Daily inspections required in severe environments

* Refer to “7.2.2 Belt Tension” on page 155

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Months 2000 hrs


Every 6 Months
Every 3 Months

When Needed
Every 250 Hrs

Every 12
1000 Hrs
Weekly

500 Hrs
Daily
CRUSHER
V-Belt Tension - During Initial commissioning 
Check [ after 2~3 hours with material ]
V-Belt Tension - Check 
Check Tightness of Hammers Daily During First  
40hrs Operation. Then Weekly.
Check Crushing Chamber Wear 
Lubricate Crusher Shaft Bearings ** and read 
NOTICE below
Check Drive Coupling - Alignment and Wear. 
See Crusher Manual for Other Maintenance 
FEEDER
Levelness of Feeder When Running (See Manual) 
Vibration Unit - Check Oil Level 
Vibration Unit - Change Oil (After 1st 100 hrs) 
Vibration Unit - Check Breather  
Liner Plates & General Condition 
See Feeder Manual for Other Maintenance 
CONVEYORS
Belt Alignment and Condition - Check 
Belt Tension - Check 
Skirting and Scraper Rubber Condition - Check 
Drive and Tail Drum Bearings - Grease ** 
Rollers - Check 
Overband Magnet Unit Included 

** Refer to “7.6.10 Greasing Schedule” on page 190


NOTICE DAMAGE to the Impactor will occur if the wrong grease specification is used in
autolube systems if the au tolube option is fit ted to t he QI441. Th e grease
specified for the CI421 impactor MUST BE USED in the Autolube system. Refer
to “7.6.9 Lubricants and Fluids” on page 189 for the correct specification.

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Months 2000 hrs


Every 6 Months
Every 3 Months

When Needed
Every 250 Hrs

Every 12
1000 Hrs
Weekly

500 Hrs
Daily
PRE SCREEN
Screen Mesh Tension 
Screen Mesh Wear   
Screen Tuning - Inspect   
Screen Springs - Inspect   
Top Deck and Hardox Bolts 
Check wear on bottom deck Rubber 
Screen Chutes   
Screen Bearing - Grease ** 
PAN FEEDER
Levelness of Feeder When Running (See Manual) 
Liner Plates & General Condition 
Lubricate Feeder Mechanism Bearings ** 
See Pan Feeder Manual for other Maintenance
HPTO CLUTCH
Check Oil Level 
Check Breather for clogs or obstructions 
Check Ventilation holes in bellhousing for clogs or 
obstructions
Replace system Oil and Oil Filter 
Replace the breather on top of the HPTO housing 
Replace Oil 
Every 5000 hours Internally inspect and service Refer to HPTO manual in OEM Chapter 
GENERAL
Wear Rubber - Check 
Replace Gearbox Oil on New Machines 100 Hours

Check Tension on Track Chains, Tightness on 


Track Bolts & Gearbox Oil Levels
Replace Gearbox Oil 
General Guard Condition and EffectivenessCheck 
** Refer to “7.6.10 Greasing Schedule” on page 190

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7.2.1 Testing the Emergency stop function and Battery Isolator

There are five Emergency-Stops on the QI441. Check that each Emerge ncy stop is operat ing
correctly at the start of each day of work when the machine is empty.

Check that the Isolator when engaged isolates the battery.


If any Emergency stop or isolator fails to work correctly, DO NOT allow the machine to be operational
these faulty items must be repaired before start up of machine.

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7.2.2 Belt Tension

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

Torque Arm

Locknuts

Replacing Belt
1. Open flywheel guards.
2. Slacken the belt by loosening the locknuts on the torque arm.
3. Remove old belt and place the new belt around the pulleys, taking up slack
with the torque arm, and tightening the locknuts.
4. Close flywheel guards
5. Run the impactor in maintenance mode for 1 - 2 minutes, at low engine
speed (rpm) (refer to “5 .2.2 Engine Start-up Sequ ence” on page 94)(refer
to “6.5.5 Manual Run Mode” on page 139.
6. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
7. Wait for pulleys to stop rotating

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8. Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

9. Open flywheel guards


10. Mark the belt on the tight side main span at two points, 1000mm apart.
Tension the belt until the distance between the marks has increased by the
value 5.6mm.
11. Tighten the locknuts on the torque arm
12. Close flywheel guards
13. Run the impactor, at lo w engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
14. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
15. Wait for pulleys to stop rotating
16. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40.

17. Open flywheel guards


18. Remeasure between the two marked points on the belt
19. Adjust belt accordingly (refer to “Adjusting the Belt” below)
20. Tighten the locknuts on the torque arm
21. Close the guards

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Adjusting the Belt

Before inspecting the V Belt Tension

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40

1. Open flywheel guards.


2. Take-up slack with the torque arm, and tighten the locknuts.
3. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
4. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
5. Wait for pulleys to stop
6. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40

7. Open flywheel guards.


8. Mark the belt on the tight side main span at two points, 1000mm apart.
Tension the belt until the distance between the marks has increased by the
value 4.4mm
9. Tighten the locknuts on the torque arm
10. Close flywheel guards
11. Run the impactor, at a low engine speed (rpm) (refer to “5.2.2 Engine Start-
up Sequence” on page 94), only on maintenance for 1 - 2 minutes.
12. Shut down the impactor, refer to “5.6 Machine Shut Down” on page 120.
13. Wait for pulleys to stop
14. Implement the LOCKOUT and TAG Procedure, refer to
“2.6.4 Isolation and energy dissipation” on page 40

15. Open flywheel guards.


16. Remeasure between the two marked points on the belt
17. Adjust belt accordingly.
18. Tighten the locknuts on the torque arm
19. Close the guards

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7.2.3 Maintenace to the CI421 Impactor using DC Maintenance Motor

Refer to the OEM section of this manual for the detailed instruction for the maintenace of the CI421
impactor. The QI441 has a DC Maintenance Motor fitted to allow impactor maintenance with
the Engine turned off.

Control panel
Chamber Switch
power on

To activate the DC motor


a. Turn the ignition key to the control panel power on position.

b. Make sure all Emergency stops are working correctly

c. Remove Safety Key Switch from the chamber switch

d. This will eng age the mech anical timelock on the CI42 1 impactor. This timelock
prevents the impa ctor from being ope ned for pr e determinded time period for
safety reasons. Refer to the CI421 manuals for futher information.

e. Turn the ignition key to power off postion

f. Turn the ignition key to the control panel power on position.

g. A display message should appear “ Chamber Opened “

h. Button 7 on the main menu will now have a icon of the impactor

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i. Press button 7 to Enable or Disable th e maintenance motor. A Green Halo will


appear when the function is enabled.

j. The DC pu mp can dire ctly operated by the two push butto ns mounted on the
machine.

k. Remember this function will not work until the mechanical timelock has expired.
Refer to d) above.

l. Once Maintenance has been completed return the Safety key switch.

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7.2.4 Engine Maintenance

When you purchased your QI441 you will h ave been provided with a n accompanying Operation
Manual for the engine. If for any reason you were not supplied with an engine manual or if you have
lost it please contact your local dealer to arrange replacement.

WARNING
SAFETY HAZARD
Risk of personnel Injury and or Damage to the Engine.
No Engine Maintenance should be attempted before fully reading and
understanding the accompanying engine Maintenance Manual.

Please refer to the Engine Maintenance Manual in order to carry out the following important areas of
Engine Maintenance.
• Changing The Fuel Filter
• Checking Engine Oil Level
• Changing Engine Oil
• Changing Engine Oil Filter
• Cleaning/Replacing The Air Cleaner
• Cleaning/Replacing The Air Cleaner Elements

7.2.5 Radio Remote Control battery Charging

a. Remove the battery and install it into the recharge unit.

b. Connect the recharge unit as shown.

c. Press ‘CHARGE’ or ‘FAST CHARGE’ w hen the LED is gre en on ‘READY’ the
battery charge cycle is complete.

d. Put the recharge unit in the support as shown

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7.2.6 Working at height hazard

DANGER
WORKING AT HEIGHT HAZARD
Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

7.2.7 Air Cleaner Inspection, Daily Inspection Required

1. Use a secure platform Inspection refer to “Working at height hazard” on


page 161 and inspect the indicator.
2. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40
3. Follow the instructions on the indicator. If Air Cleaner maintena nce is required
follow the instructions in “7.2.8 Air Cleaner Maintenance” on page 162.

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7.2.8 Air Cleaner Maintenance


DANGER

Breathing or inhaling dust particles will cause death or severe injury. Always work with a respirator
approved by the respirator manufacturer for the job you are doing. It is essential that the respirator
that you use protects you from the tiny dust particles which cause silic osis and which may cau se
other serious lung diseases. You should not use the product until you are sure your re spirator is
working properly. This means the respirator must be checked to make sure that it is clean, th at its
filter has been changed, and to othe rwise make sure the respirator will protect you in the way it is
meant to. Refer to “2.7.3 Dust” on page 44.
DO NOT USE compressed air to clean the filt er elements or filter body.
NOTICE DAMAGE to the engine will result.

a. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.

b. Wear the correct Personal Protective Equipment (refer to “2.2.3 Personal


protective equipment” on page 27).

c. Use a secure platform to access the air filter.

d. Remove the access cover using the retension latches

e. Remove the Primary Air Filter and any excess dust

f. Insert new Primary Filter

g. Also inspect the Safety Filter and replace if necessary

h. Re fit the access cover and secure with retension latches.

Access Cover Retentation latches

Primary Filter Safety Filter

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7.2.9 Battery Maintenance

It is recommended that the battery should be inspected on a weekly basis.

WARNING
SAFETY HAZARD

Battery contains corrosive chemicals and stored electrical energy.

Before carrying out any maintenance on the battery, stop the Engine,
disconnect the Ground Cable (-), then disconnect the Positive Cable
(+).Wear the correct Personal Protective Equipment, refer to “2.2.3 Person-
al protective equipment” on page 27.

a. Maintain Water Leve l. If your battery has removable vent cap s, you sho uld
regularly check the water leve l and add water when it is low. Always use distilled
water to fill the battery in order to prevent chemicals from contaminating the
battery. Be careful not to overfill the ven t wells. The fluid should cover the lead
plates in the battery.

b. Keep Terminals Clean. I f dirty or corroded, clean the connections with a scraper
and wire brush.

c. Keep Battery case clean. Keep the top of the battery clean of heavy dirt and oil.

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7.2.10 Checking Fuel Level, Adding Fuel and Draining fuel tank

WARNING
FLAMEABLE LIQUID HAZARD

Fuel is flammable and therefore is easily ignited and fires or explosions can
result.

Smoking and Welding is strictly prohibited while refuelling.

Wear the correct Personal Protective Equipment, refer to


“2.2.3 Personal protective equipment” on page 27.

Filler Cap

Drain bung

Checking Fuel -The fuel level of the machine can be checked by viewing the indicator “I” as shown
above. It is recommended that the tank should be filled at the end of every working day.

Adding Fuel:

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

b. The tank is filled by removing the filler cap, funnelling in the fuel until the indicator
“I” is at its highest level and replacing the filler cap.

Refer to “2.9 Safety considerations for maintenance” on page 46 for more information.

Draining the Fuel Tank

Note! the diesel tank capacity is approx 660 litres.

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

b. Remove the filler cap, select a suitable container which can store over 400 litres of
fuel and place it under the Drain Bung.

c. Remove the Drain Bung and allow the tank to fully empty.

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d. Perform any required maintenance on the tank and replace the drain bung before
refuelling and replace the filler cap.

7.2.11 Emptying the Fuel Filter Water Trap

Water trap

WARNING
FLAMEABLE LIQUID HAZARD.

Liquid likely to start a fire if exposed to sparks.


Restrict all other activity until liquid is secured in a suitable container, refer
to “2.9 Safety considerations for maintenance” on page 46.

a. Unscrew the drain bung at the bottom of the water trap and allow the water to
drain out.Ensure that the water in drained into a suitable container.

b. Tighten the drain bung when pure diesel starts to come out.

c. Dispose of waste in accordance with Environmental statement.

WARNING
CHEMICAL HAZARD
Diesel fuel is a chemical which should not contact your skin.
Wear the correct Personal Protective Equipment, refer to
“2.2.3 Personal protective equipment” on page 27.

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7.2.12 Special Considerations For Maintenance Or Repair with Welding

Before welding;
Refer to the CI421 maintance manual for welding operations of the CI421 Impactor

You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.)

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Disconnect LCD plug from the back of the Main Control Panel (See Photo below).

• Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

ISOLATOR

LCD

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7.3 Hydraulic System

It is essential the Hydraulic Sys tem is regula rly serviced in accordance


NOTICE with the Maintenance Schedule. When Maintenance is being carried out on
the hydraulics it is essential that extreme care regarding cleanliness is
practiced. Contamination of the hydraulic System will reduce working life
of hydraulic components and will increase the chances of Hydraulic Motor/
Pump Failure

WARNING
SKIN INJECTION HAZARD

Hydraulic fluid at high pressure can penetrate the skin, causing serious allergic
reaction and even death.

Always use a piece of cardboard to inspect for the signs of suspected leaks.
Never use any part of your body.
If fluid is injected into the skin, you must seek medical treatment immediately.

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal


WARNING
protective equipment” on page 27 , when performing any adjustment or
maintenance on the Hydraulic System.

7.3.1 Hydraulic Oil daily check

The hydraulic oil level must be checked on a daily basis. This is done by checking the indicator. If the
indicator is below the Lower Black Line, hydraulic oil must be added.

Indicator

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7.3.2 Hydraulic Oil is added as follows

a. All cylinders that can be retr acted should be retracted. Make sure tha t the
machine is on level ground

b. Implement the Lock out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40

c. Slowly unscrew Hydraulic Breather Filter (HT3) to release any build up of pressure
in the tank.

d. Make sure that the Return Line Filters (HT4), and the area around the return line
filters, are clean. If there is dust or dirt, use a clean cloth to remove.

e. Loosen the filter cover bolts, the cover of the Return Line Filter will start to rise
upwards , to remove the cover push back down and turn the cover. Hydraulic o il
must be added through the uncovered Return Line Filter, to make sure the
hydraulic oil is filtered on entering the tank.

f. Fill the tank to the Upper black markings on HT1. Make sure that the correct grade
of Hydraulic Oil has been selected (“7.6.7 Hydraulic Oil Requirements for QI441
Machines” on page 187)

HT1 Filter cover bolts Return line filter cover

HT2

HT3

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7.3.3 Changing The Return Line Filter


Return line filter cover

Filter cover bolts

Lifting handles

Filter Element

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Wear the correct Personal Protective Equipment
(refer to “2.2.3 Personal protective equipment” on page 27).

b. Slowly unscrew Hydraulic Breather Filter (HT1) to release any build up of pressure
in the tank.

c. Make sure that the Return Line Filters (HT2), and the area around the return line
filters, are clean. Use a clean cloth to clean with if there is dust or dirt present.

d. Loosen the filter cover bolts, the cover of the Return Line Filter will start to rise
upwards , to remove the cover push back down and turn the cover.

e. Lift out the filter element using the lifting handles.

f. Wash out the filter cover and dry with an air hose.

WARNING
SKIN INJECTION HAZARD

Fluid at high pressure can penetrate the skin, causing serious allergic reaction
and even death.
Wear the correct Personal Protective Equipment, refer to
“2.2.3 Personal protective equipment” on page 27.

If fluid is injected into the skin, you must seek medical treatment immediately.

g. Re-fit the new filter.

h. Replace cover and tighten bolts.

i. Re-attach the Hydraulic Breather Filter OR replace if necessary (2).

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7.3.4 Changing the suction Filters and Hydraulic Oil.


In the event of hydraulic pump or hydraulic motor failure, hydraulic oil and
NOTICE
NOTICE all hydraulic filters must be replaced in order to avoid contamination of the
hydraulic system.

a. All cylinders that can be retracted should be retracted.

b. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

Wear the correct Personal Protective Equipment, refer to


“2.2.3 Personal protective equipment” on page 27.

(The Hydraulic system will drain more efficiently when the Hydraulic Oil is a t a normal
operating temperature. It is therefore recommended that the Hydraulic Oil is changed
following a period of operation.)

HT1

HT3
Drain Bungs

Inspection Plates

c. Slowly unscrew the Hydra ulic Breather Cap HT1 to release any build up of
pressure in the tank.

Note! The Hydraulic Oil Tank capacity is approx. 660 Litres.


d. Drain the oil into a suitable container by removing the Drain Bungs located under
the tank. Dispose of waste in accordance to environmental statement.

e. Remove the tank inspection plates.

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f. Unscrew and remove the Suction Filter (6)

Suction
filters

QTY 3

g. It is recommended that the Hydraulic Tank be flushed out with clean Hydraulic Oil
to rid the tank of all conta minants. Dispose of waste in accordance to
environmental statement.

h. Fit new Suction Filters.

i. Re-attach the tank inspection plates.

j. Change Return Line F ilter Element. Refer to “7.3.3 Changing The Return Line
Filter” on page 169

k. Re-fill the tank with clean Hydraulic Oil between the upper and lower black lines
on HT 3.

l. Re-attach the Hydraulic Breather Filter (3).

m. Start the machine and after a short p eriod of operation re-check the hydraulic oil
level, refer to “7.3.1 Hydraulic Oil daily check” on page 167.

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7.3.5 HPTO Clutch Hydraulic Oil daily check

The hydraulic oil level must be checked on a daily basis. This is done by checking the indicator. If the
indicator is below the Lower Black Line, hydraulic oil must be added.

Indicator tank cover plate

7.3.6 HPTO Clutch adding hydraulic oil

a. Implement the Lock out an d Tag Procedure, re fer to “2.6.4 Isolation and energy
dissipation” on page 40. Wear the c orrect Personal Protec tive Equipment,
refer to “2.2.3 Personal protective equipment” on page 27.

b. Make sure the area around the tank cover plate is clean. Remove the fixings and
the tank cover plate and add the required quantity of new HPTO clutch oil. Refer
to “7.6.7 Hydraulic Oil Requirements for QI441 Machines” on page 187.

c. Replace the tank cover plate and secure the fixings.

7.3.7 HPTO CLutch Lubrication tank Suction Filter change

a. Implement the Lock out an d Tag Procedure, re fer to “2.6.4 Isolation and energy
dissipation” on page 40. Wear the c orrect Personal Protec tive Equipment,
refer to “2.2.3 Personal protective equipment” on page 27.

b. Make sure the area around the tank cover plate is clean. Remove the fixings and
the tank cover plate.

c. Drain the oil into a suitable container by removing the Drain Bungs located under
the tank. Dispose of waste in accordance to environmental statement.

Note! The HPTO Clutch Hydraulic Oil Tank capacity is approx. 80 Litres.

d. It is recommended that the Hydraulic Tank be flushed out with clean Hydraulic Oil
to rid the tank of all conta minants. Dispose of waste in accordance to
environmental statement.

e. Screw off the old suction filter and replace with a new suction filter.

f. and add the required quantity of new HPTO clutch oil. Refer to “7.6.7 Hydraulic Oil
Requirements for QI441 Machines” on page 187.

g. Replace the tank cover plate and secure the fixings.

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7.3.8 HPTO Oil filter Replacement

a. Implement the Lock out an d Tag Procedure, re fer to “2.6.4 Isolation and energy
dissipation” on page 40. Wear the c orrect Personal Protec tive Equipment,
refer to “2.2.3 Personal protective equipment” on page 27.

b. Make sure the area around the filter is clean.

c. Place a suitable container under the filter to catch any oil spillage.

d. Twist the old filter off and dispose of waste in a ccordance to environmental
statement.

e. Twist on the new filter.

f. Restart the engine, Refer to “5.2.2 Engine Start-up Sequence” on page 94 and
let the engine idle for 5 minutes to allow the filter ti fill.

g. The oil pressure will fall slight until the filter has re-filled.

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7.4 Track Maintenance


ALWAYS
1. Park the machine on flat, level ground. If it is necessary to park the machine on a
gradient, the tracks should be solidly blocked.
2. Make sure the terr ain the mach ine is wo rking on is firm enough to ade quately
support the machine.
3. Make certain the machine is tracked at least 10 m in either direction on a
daily basis to minimise the risk of track chain seizure.
4. Make sure the track systems are free from debris before moving the machine.
5. Make certain the tracks are not frozen to the ground before moving the machine.

NEVER
1. Attempt to track the machine if there is any build up of mate rial around the tracks
and drive sprockets.
2. Attempt to track the machine if the tracks are frozen to the ground.
3. Push or tow the machine when unable to free itself.

Working Conditions
If your machine will be working in materials which cause corrosion to carbon steel you must replace
standard tracks with lubricated tracks to avoid seizure o f the track joints. Lubricated tracks are
available as an optional extra from ne w or as a retrofit for customers entering adverse working
conditions.Contact Sandvik Mining and Construction Mobile Crushers and Screens Ltd.

7.4.1 Checking the Track Tension

Track Sag
Track Cover Plate

a. Track the QI441 a minimum of 2 metres in a forward direction on level ground.

b. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

c. Measure the sag on the top part of the track on the longest section unsupported
track as shown.

d. The sag should be between 5mm and 15mm.

e. IF the measured track sag is a bove 15mm the tracks need tightened; and if the
track sag is below 5mm the tracks need loosened.

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7.4.2 Tighten the Tracks

a. implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Loosen the two screws and remove the aperture cover
from the side of the track frame.

b. Ensure the grease fitting and grease gun adaptor are clean; ingress of dirt into the
grease fitting can result in failure.

c. Connect a grease gun to the grease fitting and add grease until the track tension
is within the specified values given in the previous section.

d. Drive 50 metres forward and 50 metres backwards an d repeat the above


procedure if the track slackens.

e. Replace the aperture cover.

7.4.3 Loosen the Tracks

a. Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40. Loosen the two screws and remove the aperture cover
from the side of the track frame.

b. Loosen the grease fitting, by turning in an anti-clockwise direction, using gradual


increments until the grease begins to be expelled.

c. Care must be taken not to loosen the grease fitting too quickly.

d. When the correct track t ension has been obtained, tighten the grease fitting by
turning in a clockwise direction and clean away all traces of extruded grease. Be
sure not to overtighten the grease fitting.

e. Replace the aperture cover.

If tracks fail to loosen after the grease fitting has been loosened: DO NOT
attempt to remove the tracks or disassemble the track tensioner. It is possible that
running the tracks a s hort distance in both d irections with the grease fitting
loosened may help to expel the grease.

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7.4.4 Track Drive Units

The first oil replacement for the gearbox is to be carried out after 100 hrs. Thereafter replace the oil
every 1000 hrs or at least once a year. The oil level should be checked every 250 hrs or every month
– whichever comes first.

a. Oil Filling

• To fill, track the machine until the gearbox casing is level with a plug positioned
at12 o’clock as shown below.

• Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

• Unscrew the 2 plugs and fill from the upper plug until oil reaches the level of the
lower hole.

Oil Level

Maximum Level

b. Oil Draining

• Implement the Lock Out and Tag Procedure, refer to “2.6.4 Isolation and energy
dissipation” on page 40.

• To drain, track the machine until a plug is at 6 o’clock position as shown below.

• Unscrew both plugs and allow all oil to discharge into a suitable container. Dispose
of waste oil in a safe approved way.

Ventingl

Drain Portl

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7.5 Tensioning Conveyor Belts on the Standard QI441

7.5.1 Tensioning the Natural Fines Conveyor Belt

NIP POINT HAZARD Conveyor belt tension can only be VISUALLY checked
WARNING
with the conveyor belt running. Adjustment of conveyor belt tension should
only be attempted by trained and authorised personnel. If you have any
concerns regarding training on the procedure, or the performance of the
adjustments themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking


proper instruction and/or obtaining adequate supervision.

Before tensioning the belts ensure that they are free from obstruction and that any excess material
is removed. If any rips/tears are discovered do not operate the machine until the belt ha s been
repaired.

1. Implement the LOCKOUT and TAG PROC EDURE, refer to “2.6.4 Isolation and
energy dissipation” on page 40.
2. Loosen bearing bolts on both bearings (left and right hand side) of the idler drum
just enough to allow movement for adjustment.
3. Start the engine and conve yor (“6.5.1 Start-up Sequence For Running the
Crusher” on page 133).
4. Tighten belt ad justers evenly (left and right hand side) until the required belt
tension is obtained.
5. Implement the LOCKOUT an d TAG PROCEDURE (“2.6 .4 Isolation and ene rgy
dissipation” on page 40).Re-tighten the bearing bolts..

Belt adjuster

Bearing Bolts

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7.5.2 Tensioning The Main Conveyor belt


NIP POINT HAZARD
Conveyor belt tension can only be VISUALLY checked with the conveyor belt
running. Adjustment of conveyor belt tension should only be attempte d by
trained and authorised personnel. I f you h ave any concerns regarding
training on the procedure, or the performance of the adjustments
themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking


proper instruction and/or obtaining adequate supervision.

Before tensioning the belts ensure that they are free from obstruction and that any excess material
is washed away. If any rips/tears are discovered do not operate the machine until the belt has been
repaired.

1. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.
2. Use a secure platform, refer to “7.2.6 Working at height hazard” on page 161.
3. Tighten the belt by adjusting both belt adjusters (left and right hand side) evenly.
4. Start the engine and conveyor. (“6.5.1 Start-up Sequence For Running the
Crusher” on page 133)
5. Inspect the tension of the belt and if more tension is required repeat steps 1
to 4 as necessary.

Belt adjuster

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7.6 Tensioning Conveyor Belts on the QI441 with Hanging Screen

7.6.1 Tensioning the Fines Conveyor Belt


NIP POINT HAZARD
Conveyor belt tension can only be VISUALLY checked with the conveyor belt
running. Adjustment of conveyor belt tension should only be attempte d by
trained and authorised personnel. I f you h ave any concerns regarding
training on the procedure, or the performance of the adjustments
themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking


proper instruction and/or obtaining adequate supervision.

Before tensioning the belts ensure that they are free from obstruction and that any excess material
is washed away. If any rips/tears are discovered do not operate the machine until the belt has been
repaired.

1. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.
2. Use a secure platform, refer to “7.2.6 Working at height hazard” on page 161, to
loosen the locknuts on the left and right hand sides.
3. Tighten the belt by adjusting both belt adjusters (left and right hand side) evenly.
4. Re-tighten the locknuts (left and right hand side).
5. Start the engine and start the conveyor. (“6.5.1 Start-up Sequence For Running
the Crusher” on page 133)
6. Inspect the tension of the belt and if more tension is required repeat steps 1
to 5 as necessary.

Belt adjuster Locknut

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7.6.2 Tensioning the Recirculating Conveyor and Stockpile Conveyor Belts


NIP POINT HAZARD
Conveyor belt tension can only be VISUALLY checked with the conveyor belt
running. Adjustment of conveyor belt tension should only be attempte d by
trained and authorised personnel. I f you h ave any concerns regarding
training on the procedure, or the performance of the adjustments
themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking


proper instruction and/or obtaining adequate supervision.

Before tensioning the belts ensure that they are free from obstruction and that any excess material
is washed away. If any rips/tears are discovered do not operate the machine until the belt has been
repaired.

1. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.
2. Use a secure platform, refer to “7.2.6 Working at height hazard” on page 161, to
loosen the locknuts on the left and right hand sides.
3. Tighten the belt by adjusting both belt adjusters (left and right hand side) evenly.
4. Re-tighten the locknuts (left and right hand side).
5. Start the engine and start the conveyor. (“6.5.1 Start-up Sequence For Running
the Crusher” on page 133)
6. Inspect the tension of the belt and if more tension is required repeat steps 1
to 5 as necessary.

Recirculating Conveyor - Head Section Stockpile Conveyor - Head Section

Adjuster

Adjuster Locknut Locknut

Recirculating Conveyor - Tail Section Stockpile Conveyor - Tail Section

Adjuster Adjuster

Locknut Locknut

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7.6.3 Tensioning the Oversize and Midsize Transfer Conveyor Belts


NIP POINT HAZARD
Conveyor belt tension can only be VISUALLY checked with the conveyor belt
running. Adjustment of conveyor belt tension should only be attempte d by
trained and authorised personnel. I f you h ave any concerns regarding
training on the procedure, or the performance of the adjustments
themselves, contact your distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tension without first undertaking


proper instruction and/or obtaining adequate supervision.

Before tensioning the belts ensure that they are free from obstruction and that any excess material
is washed away. If any rips/tears are discovered do not operate the machine until the belt has been
repaired.

1. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.
2. Tighten the belt by adjusting both belt adjusters (left and right hand side) evenly.
3. Start the engine and start the conveyor. (“6.5.1 Start-up Sequence For Running
the Crusher” on page 133)
4. Inspect the tension of the belt and if more tension is required repeat steps 1
to 3 as necessary.

Belt adjuster

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7.6.4 Tracking the Conveyor Belts

There are several factors that can have an effect on the tracking of the conveyor belts:
• Misalignment of trough roller sets,
• Misalignment of return rollers
• AND / OR incorrectly adjusted Drum Bearings.

Conveyor Plan View Conveyor Section View

If a conveyor belt is tracking off to the left or right the situation should
NOTICE
be remedied immediately. If action isn’t taken the belt life will b e
shortened and through put wont be as efficient due to spillage.

DANGER
WORKING AT HEIGHT HAZARD
Make sure correct procedures are followed FOR the tasks that are done at
height. Falling may cause injury or death. Always use a secure platform.

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Required Action;

1. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.

2. Check alignment of the trough sets and return rollers and make sure that they are
mounted at 90 Degrees to the conveyor frame about the central axis.
3. Run appropriate conveyor and observe the way the belt is tracking.

WARNING
NIP POINT HAZARD

Conveyor belt tracking can only be visually checked with the conveyor belt
running.

Adjustment of conveyor belt tracking should only be attempted by trained and


authorised personnel. If you have any concerns regarding training on the
procedure, or the performance of the adjustments themselves, contact your
distributor or the manufacturer.

DO NOT attempt to adjust conveyor belt tracking without first undertaking proper
instruction and/or obtaining adequate supervision.

IF THE B ELT IS TRACKING TO THE LEFT ADJUST THE LEFT ADJUSTER . IF THE BELT IS
TRACKING TO THE RIGHT ADJUST THE RIGHT ADJUSTER.

4. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.

5. Remove the appropriate conveyor guards if applicable.


6. Loosen the appropriate bearing bolts. if applicable.
7. Re- fit and secure the guard if applicable.
8. Adjust the bearing drum adjuster.
9. Restart the machine and run the conveyor inspect the tracking of the belt.
10. If more adjustment is required repeat steps 4. to 9.
11. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40.
12. Remove the guard and re-tighten the bearing bolts if applicable.
13. Re- fit and secure the guard.

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7.6.5 Removing and Installing Screen Media

Lower the primary Screen Box

a. Raise the secondary screen box off the locating pins on both sides by operating HC13, refer
to “4.3.3 Hydraulic Control Banks with Hanging Screen [ QI441 HS ] Option Fitted” on page
87.

Working Positon

b. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform remove the locating pins.

c. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102 to raise the secondary screen b ox up to the t ransport postion by
operating HC13

Locating pins Transport


Positon

d. Implement the Lockout and Tag Procedure, refer to “2. 6.4 Isolation and ene rgy
dissipation” on page 40. Using a secure platform Insert the locating pins. .

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e. Before changing screen mesh check that the capping rubber is in good condition.
Replace if necessary

f. Insert mesh into the box on the required level and anchor one end around the front
mesh hook.

g. Rest the screen mesh on the cross supports and using the torque arm’s either
side of the screen box extend the tension spring bar along the side plate slots until the
correct tension is achieved.

Tension spring bar

Mesh

Front mesh hook

Torque Arm

h. Restart the engine and refer to “5.3.3 Procedure to engage Auxiliary Controls”
on page 102 and run the screen box motor's, if the meshes rattle or make any noise,
repeat steps d. to h.

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7.6.6 Maintenance Data

a. Adjustment Data

Engine Speed 1100rpm (idle)/1800 - 2100rpm (run)


Feeder Speed 500-1000rpm
Crusher Speed 540rpm at 1800rpmengine speed (approx)

b. Fluid Capacities
Engine Coolant Caterpillar-38.0ltr.

Engine Oil including Filter Caterpillar-40.0ltr

Hydraulic Tank 660ltr. (146 gal)


Fuel Tank 660ltr (146 gal)
Feeder Shaft (each) 1.2ltr
Feeder Gears 4.6ltr
Track Gearbox (each) 5ltr

c. Pressures
Crusher Drive Charge Pressure 22bar (320 psi)
Crusher Drive Max Pressure 350bar (5075 psi)
Crusher Toggle Tension Pressure 135-155bar (1960-2250 psi)
Track Drive Pressure (max) 300bar (4350 psi)
General Pressure (max) 210bar (3050 psi)

7.6.7 Hydraulic Oil Requirements for QI441 Machines

a. Basic Requirements for the Hydraulic Oil Quality

• Viscosity recommended operating range – 12-60 cSt.


• Min. viscosity 12 cSt at operating temperature.
• Max. viscosity 1000 cSt at starting temperature (Intermittent).
• Cleanliness level - ISO 4406 Class 22/18/13

Unless otherwise mentioned, the factory fill oil is a special hydraulic oil of ISO VG 46 class. The
maximum recommended operating temperature with this oil type is about +80°C (175°F) and
minimum recommended starting temperature is about -20°C(-5°F), which makes it suitable for use
all year round in most operating conditions. Below are some examples of oil brands meeting these
requirements:

• Maxol Multivis 46
• BP Energol SHF 46
• Esso Univis N 46
• Shell Tellus Oil T 46
• Mobil DTE 15

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b. Winter Conditions.

In cold climate conditions, when the operating temperature of the oil stays below +60°C (140°F), the
use of a special hydraulic oil of ISO VG 32 class is re commended the max.allowable operating
temperature with this oil type is about +65°C (150°F) and min. allowable starting temperatu re is
about -30°C (-20°F). Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 32
• BP Energol SHF 32
• Esso Univis N 32
• Mobil DTE 13
• Shell Tellus Oil T 32

c. Summer Conditions.

In hot climate conditions, when the ambient temperature exceeds + 35°C (95°F), the use of a special
hydraulic oil of ISO VG 68 class is recommended. The max. allowable operating temperature with
this oil type is about +90°C (195°F) and min. allowable starting temperature is about -10°C (14°F).
Below are some examples of oil brands meeting these requirements:

• Maxol Multivis 68
• BP Energol SHF 68
• Mobil DTE 16

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7.6.8 Hydraulic Oil Requirements for HPTO Clutch

NOTICE Using any fluid other than the approved oil may significantly affect
the performance and function of the HPTO uni t and may void
warranty.

Below -4°F (-20°C) -4° TO 32°F (-20° TO 0°C) Above 32°F (0°C)

Caterpillar Arctic Mobilfluid LT Mobilfluid 424 - PREFERRED


(Cold Weather) TDTO CHOICE
- Caterpillar TDTO (10W ONLY) Caterpillar TDTO (10W ONLY)
- Shell Spirax S4 TXM Shell Spirax S4 TXM
- - Vermeer VMF Ultra Gold

7.6.9 Lubricants and Fluids

INTERNATIONAL
COMPONENT SAMPLE
SPEC
CAT ENGINE CAT CH4 (15W40) CAT CH4 DEO

CAT Anti-Freeze CAT EC-1 CAT ELC

General Grease Lithium EP2 Shell Alvania EP2

Track Gearbox SAE 80W-90 (GLS) Shell 80W/90

Primary Feeder ISO VG 220 Shell omala Oil 220

Pan Feeder Contact Sandvik Mobil Unirex N3 NLGI3


SAE 30 Caterpillar TDTO (SAE 30
Fluid Clutch
ONLY)
Impactor CI4112 Contact Sandvik Castrol Optimol PD2

Drive Belt System - Idler Contact Sandvik Mobil Unirex N3 NLGI3


Drum

Note! Fluid Clutch oil grade SAE 30 only to be used when oil temp never
goes below 0 degrees.

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7.6.10 Greasing Schedule


Quantity of
Description Frequency No. of Bearings
Grease
1) Drive Belt Pulley
a) Tension Pulley 40 Hours 2 3g
(Drum)
b) Tension bracket 250 Hours 2 7g
pivot bearings
c) Idler Pulley 40 Hours 2 3g

d) Idler Drum* 40 Hours 2 3g

2) Natural Fines 250 Hours 4 7g


Conveyor
3) Prescreen 40 Hours 2 16g

4) Stockpile 250 Hours 4 7g


Conveyor
5) Recirculating 250 Hours 4 7g
Conveyor
6) Oversize Transfer 250 Hours 4 7g
Conveyors
7) Midsize Transfer 250 Hours 4 7g
Conveyors
8) Fines Conveyor 250 Hours 4 7g

9) Main Conveyor (& 250 Hours 6 7g


snub drum bearings)
10) Impactor
a) Curtain Pivot 250 Hours 2 7g
Points Rh/Lh
b) Shaft Bearings 40 Hours 1 44g
Rh/Lh
11) Overband 250 Hours 4 7g
Magnet
12) Pan Feeder* 100 4 7g

13) Trap door & 250 2 7


diverter chute
bearings

* The Idler Drum and Pan Feeder uses High Temperature Grease - Mobil Unirex N3 NLGI3. Refer
to “7.6.9 Lubricants and Fluids” on page 189.

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11 9 10

6 7 5 1 2 3

10 11

3 13 12 4 8

Grease Point 1 a d

b c

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Grease Point 2

Grease Point 3

Grease Point 4 Grease Point 5

Grease Point 6 & 7


Grease Point 8

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Grease Point 9

Grease Point 10 Grease Point 11


a a

a b a

Grease Point 12 Grease Point 13

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The frequency of the schedule above is recommend for normal working conditions. the frequency
should change if the machine is operating in

• conditions which deviate in temperatures,

• environments with excessive contamination

• excessive operating temperatures

Visually inspect all bearings daily.

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7.6.11 Care of chrome

The following information should be used in order to maximise the lif e of the Chrome Rods. All
hydraulic rods must be greased to protect against corrosion.A full protective coverage of the chrome
is required.

The grease must be applied at the following stages:


• Assembly
• Before Storage and Transportation
• After Initial Setup
• Every 100 Hours thereafter (the responsibility of the customer)

The greases below are recommended by the manufacturer:


1. Cazar K Adhesive Water Resistant Grease
2. Shell Alvania Grease Wk2

Cleaning
Nitric Solvent (without Chlorate) is re commended in necessary cleaning of Chrome. The use of
anything else may harm or reduce the protection of the chrome.

WARNING
SAFETY HAZARD
Nitric Solvents contains corrosive chemicals.
Do not allow contact with any exposed body parts.

Wear the correct Personal Protective Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

Implement the lock out and tag procedure,refer to


“2.6.4 Isolation and energy dissipation” on page 40, before starting this operation.

Only clean the chrome if contaminated*

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8.0 Trouble Shooting and Engine Warranty

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8.1 Trouble Shooting Safety


Please refer to“ 2.0 Safety Section - Safety and Environmental Instructions” on page 13 of this
manual for additional information on safe operation, maintenance and repair of the machine. To
ensure maximum safety, ALWAYS read this section carefully BEFORE carrying out any work on
the equipment or making any adjustments. Do not attempt operation, maintenance or repair with
out first consulting all pertinent safety information.

8.1.1 Who is at Risk

• Operators, Maintenance Personnel,

• Subcontractors and anybody else in the vicinity of the machine

8.1.2 Managing Work related Hazards with a Risk Assessment

You must always perform a local risk assessment before starting a task.
This assessment, makes sure that you stop and think about what you are going
to be doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

8.1.3 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to

“2.6.4 Isolation and energy dissipation” on page 40.

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8.2 Machine Faults

8.2.1 Engine Faults (Engine Control Unit)

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8.2.2 Engine Diagnostic Codes

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8.3 Using the Proportional Spool Valve System (PSVS) controls to


Diagnose Hydraulic or Electrical Faults

Overview
The function of the PSVS controls is to receive electrical commands from the Control panel and
then the PSVS controls will operate the hydraulic control levers. This allows the operator to
diagnose non responsive commands from the Control Panel.
The PSVS levers are self returning, so if a constant function is required then the corresponding
lever needs to be manually held in position for the same duration. Once the lever is released the
flow of hydraulic oil to the function is stopped.

8.3.1 Service Engineer Selection for PSVS Diagnosis


The use of the PSVS controls is ONLY Permitted by trained and authorised Service Engineers.

WARNING RANDOM MACHINERY OPERATION HAZARD

Hazard from random operation of machine components such as flying


material from conveyors or crushing chambers, crushing from
movements of the tracks, nip and entrapment hazard as conveyor may
start at random.
The PSVS controls MUST not be used to commission or operate the
machine.
When using the PSVS controls ONLY SERVICE PERSONNEL should be
in the area of the machine.

8.3.2 PSVS Diagnosis for Hydraulic or Electrical Faults


If a desired function is not operating e.g. the main conveyor will not start from the Control Panel,
check for movement of the relative PSVS control lever, no movement indicates a initial electrical
fault. If the PSVS control lever moves and the function does not work, then the fault is hydraulic
related. Alternatively manually operate the corresponding lever as shown below. If the Main
conveyor STARTS then the fault is electrical related

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Note! The levers for the hydraulic controls have been removed and are stored in the toolbox.
They are easily attached and they should be removed before the machine is allowed to
return to normal operation.

1
2

3
4
5
6 7 8 9 10 11 12 13

LH Track Product Dirt Conveyor Impactor Primary


Hydraulic Oil Cooler
forward Conveyor ON Inlet Raise Feeder ON
Fan Forward
ON
1 2 3 4 5 6

Hydraulic Oil Cooler LH Track - - Impactor -


Fan Reverse backward Inlet Lower

Top Apron Main Conveyor UnderPan PreScreen Recirculation RH Track Recirc


Open Raise Feeder ON ON Screen ON forward conveyor
7 8 9 10 11 12 13
Main Conveyor auxiliary Auxiliary - RH Track Auxiliary
Top Apron Lower (recirc (side conv backward (jack legs &
Close auxillaries) & hopper main conv)
doors)*

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8.4 Commissioning and Engine Warranty

8.4.1 Commissioning and Warranty Registration


The Sandvik Service Engineer who has been designated to Commission this QI441 will have an
electronic version of the Commissioning and Warranty Registration form [CWR].

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8.5 CAT Register Instructions

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8.5.1 CAT C Series Warranty Statement

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9.0 Spare Parts

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9.1 Spare Parts

9.1.1 Spare Parts illustrations

This manual sets out details of available spares for the QI441 Crushing Machine. The parts list takes
the form of a number of ‘explode d’ illustrations of the various machine assemblies. Components
illustrated have reference numbers, which can be cross-referenced with the corresponding Parts list.

This list includes:

a. Illustration Reference Number

b. Actual Part Number

c. Part Description

d. Quantity of Parts per Unit Assembly

9.1.2 Ordering Procedure:

To ensure correct delivery of your replacement part when ordering please quote:

a. Machine, Model and Serial Number

b. Year of Manufacture

c. Actual Part Number

d. Part Description

e. Illustration Reference Number and Page Number

f. Quantity Required

This information will enable us to supply the part with a minimum of delay.

contact email address

tsdaftermarket.mobiles@sandvik.com

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9.1.3 Managing Work related Hazards with a Risk Assessment


You must a lways perform a local risk assessment before starting a task . This
assessment, makes sure that you stop and think about what you are going to be
doing before you begin work:

• Identify potential hazards that could impact you, your workmates, the
environment, your equipment and/or work method while you are performing the
task.

• Assess the hazards to determine what scale of control is required (apply controls
to manage the risk.

• Use the Correct Personal Protection Equipment, refer to “2.2.3 Personal


protective equipment” on page 27.

• Do not wear loose or baggy clothing which could become caught in the moving
parts of the machine.

• Do not Climb on The Machine – Always use the Access Points and Platforms or
other approved Access Equipment as required

9.1.4 When carrying out maintenance or adjustment

Implement the LOCKOUT and TAG Procedure, refer to


“2.6.4 Isolation and energy dissipation” on page 40.

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9.2 Machine Assemblies

9.3 Top Level

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9.4 Hydraulic Water Pump

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9.5 Vbelt Guard

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9.6 Pre Screen

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9.7 Chassis Complete

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9.7.1 Chassis Tower

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9.7.2 Crusher Drive Tensioning

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9.7.3 Turnbuckle Assembly

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9.7.4 Jack Leg

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9.7.5 Oil cooler and Walkway assembly

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9.8 Maintenance Platform

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9.8.1 Interlock Kit - (881.0210-00)

6
5

No. Part No. Description Qty


1 881.0212-00 Mechanical Time Delay Unit 1
2 881.0211-00 Isolation Switch 1
3 881.0173-00 Access Interlock Bolt 3
4 881.0213-00 Spacer Kit 1
5 881.0174-00 Sealed Keys 4
6 881.0175-00 Dust Caps 8
7 881.0215-00 Rubber Cap Retainer Kit 1

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9.9 Impactor Assembly Complete

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9.9.1 Crusher Inlet Chute

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ID:QI441.en.ver.1
Spare Parts qi441

9.9.2 Diverter Chute

238 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 239
ID:QI441.en.ver.1
Spare Parts qi441

9.9.3 Impactor Chute

240 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 241
ID:QI441.en.ver.1
Spare Parts qi441

9.10 Hydraulic Control Box

242 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 243
ID:QI441.en.ver.1
Spare Parts qi441

9.11 Natural Fines Conveyor

244 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 245
ID:QI441.en.ver.1
Spare Parts qi441

246 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 247
ID:QI441.en.ver.1
Spare Parts qi441

9.12 Powerunit

248 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 249
ID:QI441.en.ver.1
qi441

Parts List
ITEM PART No. DESCRIPTION QTY
1 cb0102 QI440 CAT C13 3A POWERPACK 1
2 en9602 CAT C13 TIER 3A 1
3 CN6071 ANTIFREEZE SHELL SAFE 1000 IBCPRICE PER LITRE 36
4 CN6125 RIMULA SIGNIA ENGINE OIL 36

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
Powerpack - Tier 3A

ORIGINAL ISSUE
This drawing and all the enclosures belong to us. They must not be copied

given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the

REV ECO DESCRIPTION DATE CHANGED BY


or duplicated - neither in original, nor in modified form - shown to or

REVISION HISTORY
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK KL KL 1:8 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS Weight. 4699.86 kg Sheet.
1 of. 1
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
9.12.1
Date. Drawing Size.
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
3.2 15/08/2011 A2

support of the existing law.


QI440 TIER 3A EU PRE BUY POWERPACK
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
Spare Parts

DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm


QI4403APPEUPB

250
FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°
qi441

FIT SOOT GUARD UP SIDE


DOWN FOR TRANSPORT

63 B18460000 TIER IV C13 PRE-CLEANER SUPPORT BRACKET 1


62 CB0209 VORTEX PRE-CLEANER KIT (VIRGIS FILTER) 1
61 EN10003 PSD 12 AIR CLEANER ASSEMBLY LONG VERTICAL BLUE MEDIA 1
(NON PRE-CLEANER TUBED OR SCAVENGE) 6" INLET & 6"
OUTLET
60 RU1408 RUBBER TO SUIT B12360000 BATTERY HOLDER 1
59 FD1003 800N GAS STRUT 2
58 FD1505 GAS STRUT FORK END 4
57 b18610000 SOOT GUARD C13 1
56 CB0210 EXHAUST GUARD ASSEMBLY CAT C13 1
55 EL9775 PTTECH 14" CLUTCH MASTER UNIT - CMCMU-008-DA 1
54 10-29-9295 QI440 POWERRPACK HOSE KIT 1
53 B18420000 C13 TIER 4 CLUTCH BRACE 1
52 ex7008 BECOOL RADIATOR COMPLETE TO INC BEC960,BECC0394240, 1
BECC0180380
51 cb0083 TIER IV C13 CLUTCH POWERPACK - QI440 1
50 HV8589 SAUER DANFOSS PROPORTIONAL FAN CONTROL HIC, 1
ALLOWING REVERSE FLOW RFD-120-PRV-24L-DE-S-210-6B
49 HP8860 63CC SAE B 13 TOOTH CW PUMP 1
48 HP8828 19cc ANTI-CLOCKWISE PUMP (SD NO. 1112046500) 1
46 HF9917 PT-TECH WET CLUTCH FILTER ASSEMBLY - CHYFA-001-D 1

ID:QI441.en.ver.1
44 ex7014 3-TUBE WIRE WOUND OIL COOLER BECC0126380 1
43 EN9922 O' RING I/D Ø127mm, 3mm DIA MATERIAL 2
42 EN9921 O' RING I/D Ø82.5mm, 3mm DIA MATERIAL 1
41 EN9754 QH440 ENGINE KIT C13 3A 1
36 EL9716 12 VOLT HEAVY DUTY 725 BATTERY (725TX) COLD CLIMATE 2
USEAGE
34 CB0184 CLUTCH DRIVE POWERPACK SEALING RUBBER KIT 1
33 CB0093 TIER IV CENTRAL CORE POWERPACK COMPLETE 1
32 BT9986 PT TECH TORSIONAL COUPLING TO SUIT CAT C13 1
31 BT9985 PT TECH WET CLUTCH - HPTO14 FLEX HOUSING ASSY 1
29 B17170000 CAT C13 TIER 3A FUEL FITLER BRACKET (PRIME PUMP) 1
28 B17130000 C13-3A BELT GUARD 1
27 B16880000 EXTERNAL FILTER SHROUD FRONT 1
26 B16870000 EXTERNAL FILTER SHROUD ASSY REAR 1
25 B16820000 EXTERNAL DOUBLE FILTER BRKT 1
24 B16520000 TIER IV PP BULKHEAD BLANKING PLT 1
23 B16440000 CAT C9 FUEL FILTER BRACKET 1
22 B16240000 P.T. TECH 14" MANIFOLD MOUNTING BRACKET 1
21 B16000000 TIER 4 PROPORTIONAL VALVE MTG BRKT 1 AIR CLEANER CHANGED AND ORIENTATION ALTERED;
20 B15960000 C13 TIER 3A TURBO COVER ARRGT 1 EN10003 REPLACES EN10003. PRE-CLEANER KIT CB0209
19 B15880000 MOUNTING BRACKET(FUSE B0X) 1 B 8798 x1 & PRE-CLEANER SUPPORT BRACKET B18460000 x1 02/04/12 STALBOT

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ADDED. SHROUD B14040000 x1, ELBOW EN9623x1 &
15 B14620000 BRACKET ASSY - TIER IV CLUTCH FILTER 1
CHECK VALVE EN9624x1 REMOVED.
14 B14590000 C13 TIER 4 CLUTCH BRACE 1mm SPACER 2 MODEL AND BOM UPDATED IN-LINE WITH BG BUILD.
13 B14580000 C13 TIER 4 CLUTCH BRACE 2mm SPACER 2 LIGHT MAST AND HANDRAIL NOT REQUIRED, ITEMS
12 B14570000 C13 TIER 4 CLUTCH BRACE 3mm SPACER 2 B15830000 x1, B15840000 x1, B15850000 x1, B17410000 x1
11 B14560000 C13 TIER 4 CLUTCH BRACE 5mm SPACER 2 A 8664 & EL9686 x2. HOSE KIT HHK0038 REPLACED WITH BG 08/03/2012 STALBOT
10 B14550000 C13 TIER 4 CLUTCH BRACE 8mm SPACER 2 EQUIVALENT 10-29-9295. CLUTCH BRACE B18420000
WAS B14540000. EL9775 x1, FD1003 x2, FD1505 x4,
7 B12370000 BATTERY CLAMP TO SUIT EL9716 12V HD BATTERIES 1
CB0210 x1 AND B18610000 x1 ADDED.
6 B12360000 BATTERY HOLDER TO SUIT EL9716 12V HD BATTERIES 1 ORIGINAL ISSUE
5 B12310000 CAT C13 TIER 4 ENGINE SUPPORT 1 REV ECO DESCRIPTION DATE CHANGED
4 14-05-0201 24V PUMP BRACKET 1 REVISION HISTORY
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
3 14-05-0200 24 volt pump 1 SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
fv5469 KL 1:10
2 10-24-1131 SAUER DANFOSS LOAD SENSING SERIES 45 AXIAL PUMP 2 WELD CLASSES ACCORDING TO CASTINGS Weight. Sheet. of.
N/A 1 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
130CC 3.2 07/03/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
1 10-21-0320 SAUER DANFOSS (FHP320-2 BA G2 A25 N E7) - for 130B 2 TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI440 CAT C13 3A POWERPACK
ITEM PART No. DESCRIPTION QTY FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
cb0102 B
Parts List ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

251
Spare Parts
qi441

52 49 41
52
44

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
57
56

ID:QI441.en.ver.1
28
46
15
48
42
22
20
2 43 31 32 23 29
mission. As to infringements hereof, legal action will be taken with the

DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK fv5469 KL 1:8 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS Weight. Sheet.
N/A 2 of. 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
support of the existing law.
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
3.2 07/03/2011 A2
QI440 CAT C13 3A POWERPACK
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
Spare Parts

cb0102 B

252
FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°
qi441

33

34

27 36

26

ID:QI441.en.ver.1
50

21
62
19

63
4

61

51 24

33

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
51

25 60 6 5 10 11 12 13 14

DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
fv5469 KL 1:15
WELD CLASSES ACCORDING TO CASTINGS Weight. Sheet. of.
N/A 3 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3.2 07/03/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI440 CAT C13 3A POWERPACK
FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
cb0102 B
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

253
Spare Parts
qi441

6 5 4 3 2 1
C
EXTEC SCREENS AND CRUSHERS LTD RETAIN THE COPYRIGHT IN THIS DRAWING (AND ANY ACCOMPANYING D0 NOT SCALE-IF IN DOUBT ASK.
SPECIFICATION ON THIS DRAWING) AND RESERVE ALL RIGHTS IN RESPECT THEREOF.
NO PART OF THIS DRAWING MAY BE REPRODUCED,COPIED OR USED AS A BASIS FOR ANY OTHER DRAWING OR
OTHERWISE REPRODUCED IN ANY MATERIAL FORM,PHOTOCOPIED,STORED IN A RETRIEVAL SYSTEM OR TRANSMITTED IN PROJECTION
ANY FORM OR BY ANY MEANS ELECTRONICAL,MECHANICAL,OR OTHERWISE,NOR MAY THIS DRAWING BE DISCLOSED TO
ANY THIRD PARTY WITHOUT PRIOR WRITTEN PERMISSION OF EXTEC SCREENS AND CRUSHERS LTD. THIRD ANGLE
Parts List
ITEM QTY PART NUMBER DESCRIPTION
1 1 881.0084-00 LATCH
D D
2 1 B12420000 C13 AFTER-TREATMENT COVER
3 1 B12430000 TIER IV R/H SUPPORT FRAME
4 1 B12480000 TIER IV P/P REMOVABLE PANEL
5 1 B12520000 TIER IV P/P SUPPORT PLT
6 1 B13920000 TIER IV C13 PT-TECH COVER
7 1 B13930000 TIER IV C13 PT-TECH PULLEY GUARD

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
8 1 B13950000 TIER IV C13 PT-TECH PULLEY GUARD FRAME
11 1 B14330000 C13 AFTER-TREATMENT SIDE DOOR VENT ASSY
12 1 B15210000 TIER IV PP AFTER-TREATMENT SIDE DOOR
14 1 B17010000 TIER IV PP PANEL SUPPORT BRACKET
15 2 B17670000 POWERPACK DOOR CATCH (LONG)
16 1 CB0196 LOCKING BOLT ASSY (TIER 4 POWER PACK DOORS)
14
17 1 FD1005 500NM GAS STRUT
18 2 FD1505 GAS STRUT FORK END 2
C 19 2 FD2007 DOOR HANDLE C
20 2 FD2102 HINGE
21 1 B18440000 TIER IV C13 VERTICAL AIR CLEANER MOUNTING PANEL
22 1 B18450000 TIER IV C13 VERTICAL AIR CLEANER P/PACK INFILL PANEL
15

ID:QI441.en.ver.1
19
3 12
20
22
15 18 17
B 19 B
20
1 6 A
8 4
21 5
16 18
7
A ( 1 : 10 )
A A
FINISHES AND GENERAL TOLERANCES
1) Tolerances and dimensions are in accordance with BS308. E XT E C S C R E E N S & C R U S H E R S LT D . DRAWN: R MURR TITLE: TIER IV C13 CLUTCH
2) Fabrication tolerances unless otherwise stated:- NOTES:
Linear dims up to 100mm B1mm / 100mm to 1000mm B2mm / over 1000mm B3mm
Machining tolerance unless otherwise stated:-
REV A: SEE ECO 6741 (20.10.10) RM
REV B: CORE SECTION CB0093 REMOVED [6791] RM
CHECKED:
POWERPACK - QI440
REV C: ITEMS REMOVED, 2 OFF B12610000 & 2 OFF DATE: 12/10/2010 DRG.No. SHT 1 OF 2 REV.
Linear dims up to 100mm B 0.25mm / 100mm to 1000mm B0.5mm FD7048. ITEMS ADDED 2 OFF B17670000, 2 OFF
Linear dims over 1000mm B1.0mm
A3 D
Spare Parts

cb0083

254
CB0196 & 1 OFF 881.0084-00. AW (22.08.2011) [7549]. MATL: SHT SIZE:
Diameters up to 150mm B0.25mm / Diameters over 150mm B0.4mm REV D: PANELS UPDATED FOR MOUNTING NEW AIR FILTER
3) Remove all burrs and sharp edges B18440000 WAS B16830000, B18450000 WAS B13960000. 2-OFF
4) Machined surfaces unless otherwise stated
3.2
B13970000 REMOVED. (13.03.2012) [8678] ST
WT (Kg): FINISH:
6 5 4 3 2 1
6 5 4 3 2 1
EXTEC SCREENS AND CRUSHERS LTD RETAIN THE COPYRIGHT IN THIS DRAWING (AND ANY ACCOMPANYING D0 NOT SCALE-IF IN DOUBT ASK.
qi441
SPECIFICATION ON THIS DRAWING) AND RESERVE ALL RIGHTS IN RESPECT THEREOF.
NO PART OF THIS DRAWING MAY BE REPRODUCED,COPIED OR USED AS A BASIS FOR ANY OTHER DRAWING OR
OTHERWISE REPRODUCED IN ANY MATERIAL FORM,PHOTOCOPIED,STORED IN A RETRIEVAL SYSTEM OR TRANSMITTED IN PROJECTION
ANY FORM OR BY ANY MEANS ELECTRONICAL,MECHANICAL,OR OTHERWISE,NOR MAY THIS DRAWING BE DISCLOSED TO
C ANY THIRD PARTY WITHOUT PRIOR WRITTEN PERMISSION OF EXTEC SCREENS AND CRUSHERS LTD. THIRD ANGLE

63

D D

C C

2470 1703

1554 1336

ID:QI441.en.ver.1
B B

1550

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
A A
FINISHES AND GENERAL TOLERANCES
1) Tolerances and dimensions are in accordance with BS308. E XT E C S C R E E N S & C R U S H E R S LT D . DRAWN: R MURR TITLE: TIER IV C13 CLUTCH
2) Fabrication tolerances unless otherwise stated:- NOTES:
Linear dims up to 100mm B1mm / 100mm to 1000mm B2mm / over 1000mm B3mm REV A: SEE ECO 6741 (20.10.10) RM CHECKED:
Machining tolerance unless otherwise stated:- REV B: CORE SECTION CB0093 REMOVED [6791] RM
POWERPACK - QI440
REV C: ITEMS REMOVED, 2 OFF B12610000 & 2 OFF DATE: 12/10/2010 DRG.No. SHT 2 OF 2 REV.
Linear dims up to 100mm B 0.25mm / 100mm to 1000mm B0.5mm
FD7048. ITEMS ADDED 2 OFF B17670000, 2 OFF
Linear dims over 1000mm B1.0mm CB0196 & 1 OFF 881.0084-00. AW (22.08.2011) [7549].
Diameters up to 150mm B0.25mm / Diameters over 150mm B0.4mm
MATL: cb0083 SHT SIZE: A3 D
REV D: PANELS UPDATED FOR MOUNTING NEW AIR FILTER
3) Remove all burrs and sharp edges 3.2 B18440000 WAS B16830000, B18450000 WAS B13960000. 2-OFF
4) Machined surfaces unless otherwise stated B13970000 REMOVED. (13.03.2012) [8678] ST
WT (Kg): FINISH:

255
6 5 4 3 2 1
Spare Parts
qi441

Parts List
ITEM PART No. DESCRIPTION QTY
1 CB0149 CAT C13 TIER 3A PIPE KIT 1
2 CB0155 C13 TIER 3A PIPE KIT FINNINGS SUPPLY OF CAT 1
COMPONENTS.
1

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
This drawing and all the enclosures belong to us. They must not be copied

given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
or duplicated - neither in original, nor in modified form - shown to or

DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK KLOWNDES KL 1:15 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS Weight. 468.53 kg Sheet.
1 of. 1
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
02/08/2011 A3
support of the existing law.
A 8736 ITEMS 1 & 2 REVISED 02/04/12 STALBOT MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
3.2
QH440 ENGINE KIT C13 3A
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ORIGINAL ISSUE DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
REV ECO DESCRIPTION DATE CHANGED BY FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
EN9754 A
Spare Parts

256
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°
ENGLAND, PHONE 01283 212121
qi441
Parts List
ITEM PART No. DESCRIPTION QTY
1 CB0168 TIER IV MULTI-PIPE SUPPORT ASSY (CHARGED AIR 1
SYSTEM)
2 CB0182 CAT C13 (3A) SILENCER BRACKET ASSY 1
3 EN9664 5" EXHAUST RAIN CAP 1
4 EN9799 CAT C13 SILENCER (CAT PART No 1N3452) 1 1 11 7 12 2 4 14 3

5 EN9800 CAT C13 TIER 3A (EXHAUST PIPE) - TURBO TO BELLOWS 1


6 EN9801 CAT C13 TIER 3A (EXHAUST PIPE) - BELLOWS TO SILENCER 1
7 EN9802 CAT C13 TIER 3A (COOLED CHARGED AIR PIPE) - COOLER 1
UNIT TO ENGINE INLET MANIFOLD
8 EN9803 CAT C13 TIER 3A (COOLANT PIPE) - LOWER ENGINE PORT 1
TO LOWER COOLER PORT
9 EN9804 CAT C13 TIER 3A (AIR INLET PIPE) - HUMP CONNECTOR TO 1
TURBO INLET
10 EN9805 CAT C13 TIER 3A (AIR INLET PIPE) - AIR CLEANER 90° 6"-5" 1
REDUCER ELBOW TO HUMP CONNECTOR
11 EN9806 CAT C13 TIER 3A (CHARGED AIR TO BE COOLED PIPE) - 1
TURBO TO COOLER UNIT
12 EN9807 CAT C13 TIER 3A (COOLANT PIPE) - UPPER ENGINE PORT 1
TO RUBBER CONNECTION
13 EN9808 CAT C13 TIER 3A (EXHAUST PIPE) - BELLOWS UNIT 1
14 EN9828 CAT C13 TIER 3A (EXHAUST PIPE) - SILENCER TAIL PIPE 1
16 EN9859 CAT C13 TIER 3A (COOLANT PIPE) - UPPER COOLER PORT 1
TO RUBBER CONNECTION
6
17 FAB1026 M10 U-BOLT 140mm CTRS 100mm LONG 1
18 FAB1024 M10 U-BOLT 76mm CTRS 90mm LONG 1
19 FAB1025 M10 U-BOLT 115mm CTRS 90mm LONG 1

13

ID:QI441.en.ver.1
5

8
10

16

19
17
18

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
fv5469 KL 1:15
SCAVANGE PIPE EN9847 x1 REMOVED. MISSING WELD CLASSES ACCORDING TO CASTINGS Weight. 449.74 kg Sheet. of.
A 8736 02/04/12 STALBOT 1 1
U-BOLTS ITEMS FAB1024, FAB0125, FAB0126 ADDED ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3.2 07/03/2011 A3
ORIGINAL ISSUE MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
REV ECO DESCRIPTION DATE CHANGED BY DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm CAT C13 TIER 3A PIPE KIT
FABRICATION ±1.0mm ±2.0mm ±3.0mm
REVISION HISTORY MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0149 A
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

257
Spare Parts
qi441

Parts List
ITEM PART No. DESCRIPTION QTY
1 EN9657 DONALDSON 6"-5" 90° ELBOW REDUCER (P143895) 1
2 EN9850 5" HUMP HOSE (FINNING SUPPLY 5S3919) 2
3 EN9851 4" SILICON HUMP HOSE (FINNING SUPPLY 7E8630) 4
1 3 3 3 5
4 EN9852 HOSE 90CM REQ'D 120mm (FINNING SUPPLY 5P1262 @ 3
240mm)
5 EN9855 CAT C13 UPPER COOLANT PIPE 2.5" SILICON HOSE 90° 2
ELBOW (FINNING SUPPLY)
10 EN9916 CAT AIR INDICATOR ELECTRONIC (CAT CODE: 281-8728) 1
11 EN9869 DRAIN TAP 3/8" NPT (FINNING SUPPLY 8F8151) 1

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
4

ID:QI441.en.ver.1
3
11
10 2 2 5
This drawing and all the enclosures belong to us. They must not be copied

ITEMS 7-9 RELATING TO SCAVANGE SYSTEM


given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
or duplicated - neither in original, nor in modified form - shown to or

REMOVED TO SUIT AIR CLEANER CHANGE; 1.5"


B 8736 HOSE EN9860 x1, DUST EJECTION HOSE EN9861 x1 03/02/12 STALBOT Designed. Drawn By. Checked. Approved. Scale. Projection. Material
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS)
& P-CLIP FOR DUST EJECTION HOSE EN9862 x1 SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK mevans KL 1:15 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
DELETED WELD CLASSES ACCORDING TO CASTINGS Weight. 18.79 kg Sheet.
1 of. 1
COOLANT ELBOWS UPDATED, ITEM 5 QTY 2 WAS ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
A 8518 14/07/11 STALBOT 04/07/2011 A3
QTY 1. ITEM 6 EN9856 REMOVED C13 TIER 3A PIPE KIT FINNINGS SUPPLY
3.2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE

support of the existing law.


Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ORIGINAL ISSUE
OF CAT COMPONENTS.
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
REV ECO DESCRIPTION DATE CHANGED BY FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0155 B
Spare Parts

258
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°
ENGLAND, PHONE 01283 212121
qi441

9.12.2

FIT SOOT GUARD UPSIDE


DOWN FOR TRANSPORT

70 FD1003
800N GAS STRUT 2
69 FD1505
GAS STRUT FORK END 4
68 RU1408
RUBBER TO SUIT B12360000 BATTERY HOLDER 1
67 EL9775
PTTECH 14" CLUTCH MASTER UNIT - CMCMU-008-DA 1
66 10-29-9295
QI440 POWERRPACK HOSE KIT 1
65 B18420000
C13 TIER 4 CLUTCH BRACE 1
64 b18610000
SOOT GUARD C13 1
63 CB0210
EXHAUST GUARD ASSEMBLY CAT C13 1
62 B18460000
TIER IV C13 PRE-CLEANER SUPPORT BRACKET 1
61 CB0209
VORTEX PRE-CLEANER KIT (VIRGIS FILTER) 1
60 EN10003
PSD 12 AIR CLEANER ASSEMBLY LONG VERTICAL BLUE MEDIA (NON 1
PRE-CLEANER TUBED OR SCAVENGE) 6" INLET & 6" OUTLET
Powerpack - Tier 3B

59 1420-16-38 MOUNTING BRACKET 1


58 1442-15-53 PUMP BRACKET 1
57 1420-15-94 PIPE BRACKET 1
56 14-05-0200 24 volt pump 1
55 HP8860 63CC SAE B 13 TOOTH CW PUMP 1
54 BT9986 PT TECH TORSIONAL COUPLING TO SUIT CAT C13 1
53 CB0189 TIER 4 CAT C13 AFTER TREATMENT SHROUD BOLTED ASSY 1
52 HF9917 PT-TECH WET CLUTCH FILTER ASSEMBLY - CHYFA-001-D 1
50 EN9755 QH440 CLUTCH CAT C13 (3B) POWERPACK PIPEWORK 1
49 HP8863 TANDEM PUMP 014/014LN06SMP3F5F4NNF5F4NNNN/NNNNNN 1
48 HP8828 19cc ANTI-CLOCKWISE PUMP (SD NO. 1112046500) 1
47 EN9922 O' RING I/D Ø127mm, 3mm DIA MATERIAL 2
46 EN9921 O' RING I/D Ø82.5mm, 3mm DIA MATERIAL 2
45 10-24-1131 SAUER DANFOSS LOAD SENSING SERIES 45 AXIAL PUMP 130CC 2
44 CB0184 CLUTCH DRIVE POWERPACK SEALING RUBBER KIT 1
43 EX7017 SINGLE TUBE WIRE WOUND FUEL COOLER 1
41 EN9927 Novibra Type RA Mount (10-00107) [60 IRH] 6
40 B17140000 C13 TIER 3B TURBO COVER ARRGT 1

ID:QI441.en.ver.1
39 B14610000 C13 TIER IV FUEL FILTER BRACKET ASSY 1
37 B16620000 CAT C13 UPPER ANTI-VIBE MTG BRKT (A/T SHROUD) 1
36 B16610000 CAT C13 UPPER ANTI-VIBE MTG BRKT (POWER PACK) 1
33 B12260000 CAT C13 TIER 4 AFTER TREATMENT SUPPORT 1
32 cb0083 TIER IV C13 CLUTCH POWERPACK - QI440 1
31 10-21-0320 SAUER DANFOSS (FHP320-2 BA G2 A25 N E7) - for 130B 2
30 HV8589 SAUER DANFOSS PROPORTIONAL FAN CONTROL HIC, ALLOWING REVERSE 1
FLOW RFD-120-PRV-24L-DE-S-210-6B
24 ex7014 3-TUBE WIRE WOUND OIL COOLER BECC0126380 1
23 ex7008 BECOOL RADIATOR COMPLETE TO INC BEC960,BECC0394240, BECC0180380 1
22 EL9716 12 VOLT HEAVY DUTY 725 BATTERY (725TX) COLD CLIMATE USEAGE 2
21 B16520000 TIER IV PP BULKHEAD BLANKING PLT 1
20 BT9985 PT TECH WET CLUTCH - HPTO14 FLEX HOUSING ASSY 1
18 B16880000 EXTERNAL FILTER SHROUD FRONT 1
17 B16870000 EXTERNAL FILTER SHROUD ASSY REAR 1
16 B16820000 EXTERNAL DOUBLE FILTER BRKT 1
15 B16240000 P.T. TECH 14" MANIFOLD MOUNTING BRACKET 1
14 B16000000 TIER 4 PROPORTIONAL VALVE MTG BRKT 1
13 1420-16-37 MOUNTING BRACKET 1
12 B14620000 BRACKET ASSY - TIER IV CLUTCH FILTER 1
11 B14590000 C13 TIER 4 CLUTCH BRACE 1mm SPACER 2

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
10 B14580000 C13 TIER 4 CLUTCH BRACE 2mm SPACER 2
9 B14570000 C13 TIER 4 CLUTCH BRACE 3mm SPACER 2
8 B14560000 C13 TIER 4 CLUTCH BRACE 5mm SPACER 2
7 B14550000 C13 TIER 4 CLUTCH BRACE 8mm SPACER 2
BOM/ MODEL UPDATED IN LINE WITH BG BUILD. LIGHT MAST ITEMS AND 4 B12370000 BATTERY CLAMP TO SUIT EL9716 12V HD BATTERIES 1
HANDRAIL NOT REQUIRED - B15840000 x1, B15830000 x1, EL9686 x2, 3 B12360000 BATTERY HOLDER TO SUIT EL9716 12V HD BATTERIES 1
B15850000 x1 & B16920000 x1 REMOVED. NEW AIR CLEANER ADDED 2 B12310000 CAT C13 TIER 4 ENGINE SUPPORT 1
EN10003 WAS EN9621. VIRGIS PRE-CLEANER KIT CBO209 AND 1 CB0093 TIER IV CENTRAL CORE POWERPACK COMPLETE 1
PRE-CLEANER TIE BRACKET B18460000 x1 ADDED. CORE POWER PACK
B 8678 14-03-12 S TALBOT ITEM PART No. DESCRIPTION QTY
NOW COMMON BETWEEN BG & SWAD, CB0093 WAS CB0200. CLUTCH
BRACE REPLACED B18420000 WAS B14540000 x1. ANTI VIBE MOUNTS Parts List
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
EN9927 WAS 864.0078-00 x6. EXHAUST TAIL PIPE GUARD CB0210 AND SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK R Catterson 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
SOOT GUARD B18610000 ADDED. BATTERY RUBBER RU1408 x1 ADDED. WELD CLASSES ACCORDING TO CASTINGS Weight. 3875.94 kg Sheet. of.
1 3
MISSING ITEMS EL9775 x1, 10-29-9295 x1, FD1505 x4 & FD1003 x2 ADDED. ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3.2 07/03/2011 A2
ITEM 1 WAS CB0093, ITEM 13 WAS B15880000, ITEM 15 WAS B16570000, MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
A 8069 27-10-11 R Catterson TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ITEMS 19, 34, 35 & 38 DELETED, ITEM 40 WAS CB0172, ITEMS 42-59 ADDED DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI440 CLUTCH CAT C13B POWERPACK
FABRICATION ±1.0mm ±2.0mm ±3.0mm
REV ECO DESCRIPTION DATE CHANGED BY MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0100 B
ENGLAND, PHONE 01283 212121
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

259
Spare Parts
qi441

HIDDEN
55
23

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
50
40

ID:QI441.en.ver.1
47
48
45
46
15 39
49 46
65 45 47
11 10 9 8 20
7 54
24
43
52 12 8 9 10 11
7
mission. As to infringements hereof, legal action will be taken with the

DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK R Catterson 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS Weight. Sheet.
N/A 2 of. 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
support of the existing law.
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
3.2 07/03/2011 A3
QI440 CLUTCH CAT C13B POWERPACK
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
Spare Parts

DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm

260
FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0100 B
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°
qi441

1
69
70
69
14
30
58
56
44
32

69

70
64
69

63
22
4
68
3
16
31
17
18

ID:QI441.en.ver.1
37

36

53

41

33
61
13
62 21

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
60 59

1
32 65 7 8 9 10 11

DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
R Catterson
WELD CLASSES ACCORDING TO CASTINGS Weight. 3875.94 kg Sheet. of.
3 3
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3.2 07/03/2011 A3
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm QI440 CLUTCH CAT C13B POWERPACK
FABRICATION ±1.0mm ±2.0mm ±3.0mm
MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0100 B
ENGLAND, PHONE 01283 212121
ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

261
Spare Parts
qi441

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
2
2 CB0156 QH440 CLUTCH CAT C13 (3B) POWERPACK CONNECTION KIT 1
1 CB0150 QH440 CLUTCH CAT C13 (3B) POWERPACK PIPEWORK 1
given to a third party or used for manufacturing purposes without our per-

ITEM PART No. DESCRIPTION QTY


mission. As to infringements hereof, legal action will be taken with the

Parts List
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK fv5469 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
WELD CLASSES ACCORDING TO CASTINGS Weight. 69.08 kg Sheet.
1 of. 1
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
07/03/2011 A3
QH440 CLUTCH CAT C13 (3B)
3.2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
support of the existing law.
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ORIGINAL ISSUE
POWERPACK PIPEWORK
DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
Spare Parts

EN9755

262
FABRICATION ±1.0mm ±2.0mm ±3.0mm
REV ECO DESCRIPTION DATE CHANGED BY MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°
ENGLAND, PHONE 01283 212121
qi441

1
7

ID:QI441.en.ver.1
10

10 EN9957 CAT C13 TIER 3B ENGINE PIPE (COOLER UNIT TO LOWER ENGINE PORT) 1
9 CB0177 QJ341 C9.3/C9 TIER IV EXHAUST TAIL PIPE ASSY 1
8 EN9956 CAT C13 TIER 3B ENGINE PIPE (COOLER UNIT TO UPPER ENGINE PORT)(ENGINE SECTION) 1

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
7 EN9952 CAT C13 TIER 3B ENGINE PIPE (COOLER UNIT TO UPPER ENGINE PORT)(ENGINE SECTION) 1
6 EN9953 PIPE 1
5 EN9955 PIPE 1
4 EN9958 CAT C13 TIER 3B ENGINE PIPE 1
3 EN9954 CAT C13 TIER 3B ENGINE PIPE (AIR CLEANER TO TURBO - LOWER SECTION) 1
2 EN9944 CAT C9.3 TIER 3B ENGINE PIPE (AIR CLEANER TO TURBO - UPPER SECTION) 1
1 CB0168 TIER IV MULTI-PIPE SUPPORT ASSY (CHARGED AIR SYSTEM) 1
ITEM PART No. DESCRIPTION QTY
Parts List
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK R Catterson 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.

WELD CLASSES ACCORDING TO CASTINGS Weight. 48.43 kg Sheet. of.


1 1
ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
3.2 07/10/2011 A2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE
Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
QH440 CLUTCH CAT C13 (3B)
ORIGINAL ISSUE DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm
FABRICATION ±1.0mm ±2.0mm ±3.0mm POWERPACK PIPEWORK
REV ECO DESCRIPTION DATE CHANGED BY MACHINED ±0.25mm ±0.5mm ±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0150
ENGLAND, PHONE 01283 212121
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°

This drawing and all the enclosures belong to us. They must not be copied
or duplicated - neither in original, nor in modified form - shown to or
given to a third party or used for manufacturing purposes without our per-
mission. As to infringements hereof, legal action will be taken with the
support of the existing law.

263
Spare Parts
qi441

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
4
8
3
5
2

ID:QI441.en.ver.1
10
5 5
10
7
7
1
7
9 10 EN9862 P' CLIP (DUST EJECTION HOSE) (FINNING SUPPLY 5P4325) 2
6 9
9 EN9852 HOSE 90CM REQ'D 120mm (FINNING SUPPLY 5P1262 @ 240mm) 3
6 8 EN9950 P' CLIP (DUST EJECTION HOSE) (FINNING SUPPLY) 1
5
7 EN9867 2.5" 90° ELBOW (FINNING SUPPLY 3R1317) 3
6 EN9850 5" HUMP HOSE (FINNING SUPPLY 5S3919) 2
5 EN9864 4" HUMP HOSE (FINNING SUPPLY 7N2628) 5
4 EN9664 5" EXHAUST RAIN CAP 1
3 EN9873 2" SILICON HOSE (FINNING SUPPLY SILIFLEX 2481-6014) 1
2 EN9868 2" HOSE (FINNING SUPPLY 5P1259) 1
1 EN9657 DONALDSON 6"-5" 90° ELBOW REDUCER (P143895) 1
This drawing and all the enclosures belong to us. They must not be copied

given to a third party or used for manufacturing purposes without our per-

ITEM PART No. DESCRIPTION QTY


mission. As to infringements hereof, legal action will be taken with the
or duplicated - neither in original, nor in modified form - shown to or

Parts List
DRAWING TO BS 308 & NS EN22553 (WELDING SYMBOLS) Designed. Drawn By. Checked. Approved. Scale. Projection. Material
ASSEMBLY UPDATED INLINE WITH FIRST C13 3B SCREW THREADS ARE ISO METRIC COURSE PITCH IF IN DOUBT ASK R Catterson 3rd ANGLE
MEDIUM FIT UNLESS OTHERWISE STATED.
PRODUCTION BUILD. ITEM 3 EN9873 QTY 2 WAS 3. ITEM 5 24.47 kg
A 20002 28-09-12 STALBOT WELD CLASSES ACCORDING TO CASTINGS Weight. Sheet.
1 of. 1
EN9864 QTY 5 WAS 4. ITEM 7 EN9867 QTY 3 WAS 2. ITEM 9 ISO 5817 (SA 1184,095) ISO 8062-CT12 (SA 1121,300)
Date. Drawing Size.
07/10/2011 A2
EN9852 QTY 3 WAS 2. ITEM 10 P-CLIP ADDED QH440 CLUTCH CAT C13 (3B)
3.2
MACHINED SURFACES UNLESS OTHERWISE STATED TO BE

support of the existing law.


Drawing No. Revision.
TOLERANCES FOR LINEAR AND ANGULAR TOLERANCE CLASS
ORIGINAL ISSUE
POWERPACK CONNECTION KIT
Spare Parts

DIMENSIONS UNLESS OTHERWISE STATED. <100mm 100-1000 >1000mm

264
REV ECO DESCRIPTION DATE CHANGED BY FABRICATION
MACHINED
±1.0mm
±0.25mm
±2.0mm
±0.5mm
±3.0mm
±1.0mm SWADLINCOTE, DERBYSHIRE, DE11 9DU
CB0156 A
REVISION HISTORY ANGULAR ±1.0° ±0.5° ±0.25°
ENGLAND, PHONE 01283 212121
qi441 Spare Parts

9.12.3 Clutch Lube Tank

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 265
ID:QI441.en.ver.1
Spare Parts qi441

9.12.4 Diesel tank

266 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

9.12.5 Hydraulic tank

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 267
ID:QI441.en.ver.1
Spare Parts qi441

9.13 Eriez Magnet

268 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 269
ID:QI441.en.ver.1
Spare Parts qi441

9.14 Hopper Wing Plate

270 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 271
ID:QI441.en.ver.1
Spare Parts qi441

9.15 Main Conveyor

272 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 273
ID:QI441.en.ver.1
Spare Parts qi441

9.15.1 Main Conveyor Lower Section

274 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 275
ID:QI441.en.ver.1
Spare Parts qi441

9.15.2 Main Conveyor Upper Section

276 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 277
ID:QI441.en.ver.1
Spare Parts qi441

9.15.3 Main Conveyor Extension

278 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 279
ID:QI441.en.ver.1
Spare Parts qi441

9.16 Primary Feeder

280 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 281
ID:QI441.en.ver.1
Spare Parts qi441

9.16.1 Feeder

30
29
8
7

27
12

23
9
3

25
11
10

24
26
5

15
62
5

34
31

21

22

28

13
5

32
4
2

20

17

19

18

15

16

282 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Item No.
Pos. Nr. QTY ID_TC Name_TC

1 1 726.0661-901 WEAR PLATE ASSEMBLY


2 2 713.1026-001 Wear plate
3 1 726.0659-001 WEAR PLATE
4 1 713.1024-001 Wear plate
5 4 713.1028-001 WEAR PLATE
6 44 990.0236-001 Screw M12x16 DIN7991 - 8.8A3G
7 84 990.0270-001 Washer 14 DIN126 - A3G
8 84 990.0187-001 Nut M12 DIN985-8A3F
9 40 990.0236-001 Screw M12x16 DIN7991 - 8.8A3G
10 1 726.0657-001 WEAR PLATE
11 1 726.0658-001 WEAR PLATE
12 1 726.0660-001 WEAR PLATE
13 1 713.1997-901 Vibrator Unit
14 4 713.1909-901 SPRING SUPPORT
15 2 990.0851-001 Spring HF654X
16 2 723.1439-001 PURFLEX P2PU D165 - L=300MM
17 2 990.0271-001 Washer 18 DIN126 - A3G
18 1 SV1321X-P2-OP1 SPRING SUPPORT
19 1 713.1913-001 Holder For Springbase (Same as MSO-P2-OP4-001)
20 2 840.0639-00 SCREW M6S 16x140 8.8
21 36 990.0276-001 Washer 17 DIN6916 - Non plated
22 18 990.0627-001 Nut M16 DIN6915-10.9 Non plated
23 7 990.0176-001 SCREW M12X40 DIN933 - 8.8A3G
24 14 990.0270-001 Washer 14 DIN126 - A3G
25 7 990.0187-001 Nut M12 DIN985-8A3F
26 2 847.0303-00 WASHER BRB 13x30x6 FZB DIN7349
27 1 713.1998-901 Feeder Body
28 18 990.0078-001 Screw M16x60 DIN6914-10.9A3G Non plated
29 1 1440-20-92-001 PRESCREEN/FEEDER SEALING RUBBER
30 1 1440-20-93-001 CLAMP
31 4 726.4605-001 STROKE & STROKE ANGLE DECAL
32 2 726.4596-001 ROTATIONAL DIRECTIONAL DECAL
33 1 726.4607-001 GEAR OIL QUANTITY - DECAL
34 2 726.4599-001 MECHANISM OIL QUANTITY DECAL

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd. 283
ID:QI441.en.ver.1
Spare Parts qi441

Vibrator Unit 713.1997-901

17

13

12
53

45
51
24

47
14

52
33

46
15

37
2
1

11

38
43
50

21

31
37

29
34

41
49

22
3

30

23

15
5

16

26
32

44

48

45
40
4

27
25
7

19

28

42
10

20
9

18
6

39

284 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Item No.
Pos. Nr. QTY ID_TC Name_TC

1 1 713.1057-901 Frame of vibrating unit


2 2 713.1059-001 SV0921 SHAFT
3 4 713.0665-001 BEARING 22313CC W33A15
4 4 713.0666-001 INTERM RING
5 4 713.0667-001 FLING RING
6 4 713.0668-001 WEAR RING
7 4 713.0669-001 O-RING 139.3X5.7
8 4 713.0671-001 COVER
9 4 713.0673-001 O-RING 54.2X3
10 4 713.0674-001 V-RING V-75S
11 4 713.1995-001 Counterweight
12 2 713.0676-001 GEAR WHEEL
13 2 713.0677-001 LOCK WASHER MB11
14 2 713.0678-001 SHAFT NUT KM11
15 4 990.0068-001 GREASING NIPPLE M10X1 (10-01-1142)
16 36 990.0176-001 SCREW M12X40 DIN933 - 8.8A3G
17 1 713.0680-901 GUARD OF COUNTERWEIGHT
18 52 990.0174-001 Screw M10x20 DIN933 - 8.8A3G
19 52 990.0269-001 WASHER 11 DIN126 - A3G
20 44 990.0186-001 Nut M10 DIN985-8A3F
21 1 990.0222-001 Screw M16x45 DIN931 - 8.8A3G
22 6 990.0270-001 Washer 14 DIN126 - A3G
23 6 990.0187-001 Nut M12 DIN985-8A3F
24 2 713.0709-001 KEY C 16X10X90 DIN6885
25 2 713.0710-001 KEY C-16X10X55
26 1 713.1168-901 ADAPTER
27 1 990.0632-001 COUPLING JUBOFLEX 632508
28 1 713.0755-001 TENSION PLATE
29 1 713.1194-001 KEY A6.35X7X35
30 1 713.0756-001 Silicone
31 2 990.0064-001 BREATHER FFHU2015
32 2 990.0065-001 OIL PLUG R1/2"
33 2 713.0706-001 PLUG T8 DN20 R3/4" 5031
34 1 713.0704-001 SIGHT WINDOW 1INCH
35 1 713.0759-001 Gear oil ISO VG220+EP 1,9ltr
36 1 713.1363-001 Shaft oil ISO VG220+EP
37 2 713.1761-001 HEXAGON NIPPLE R 3/4
38 2 713.1760-001 EQUAL SOCKET RP3/4
39 1 713.1958-901 COUNTERWEIGHT GUARD
40 1 HM1046-IGES HM1046 74328-DAM 50CC PISTON MOTOR
41 2 840.0048-00 SCREW M6S M12X45 8.8 ZP PT.
42 1 726.0573-901 ADAPTER (MOTOR)
43 1 713.2176-001 FILLING PLUG MINTOR TSF 3/4"
44 2 726.4976-001 OIL/TEMP GAUGE
45 10 840.0074-00 SCREW M6S 16x80 8.8
46 10 847.0259-00 LOCK WASHER NL-M62 GLUE COATED
47 4 845.0009-00 NUT M6M M16 8 FZB ISO 4032
48 4 873.0693-00 Seal
49 1 713.0690-001 COVER
50 1 713.1509-001 SEAL 6X15 - 3000
51 21 BG00189806 Square washer 20x20x4..11 ROX10209 - A5G
52 23 847.0144-00 WASHER BRB 10,5x22 HB200
53 21 845.0213-00 NUT LOCK ISO 7040 M10 8 FZB

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9.17 Pan Feeeder

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9.18 HS System - Recirculating Oversize [ Option where Fitted ]

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ID:QI441.en.ver.1
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9.18.1 Recirculation conveyor

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9.18.2 HS System - Mounting Frame recirculating oversize

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9.18.3 Recirculation Fines conveyor

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9.18.4 Recirc product conv upper section complete

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Spare Parts qi441

9.18.5 Recirc product conv lower section complete

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9.18.6 Recirculation Screen

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Spare Parts qi441

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Spare Parts qi441

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9.19 Stock Pile Conveyor

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9.20 Transfer Conveyor 1440-35-00

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9.21 Transfer Conveyor 1442-35-00

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9.21.1 HS System - Recirculating Mid & Oversize [ Option where fitted ]

316 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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9.21.2 Transfer Conveyor - Recirculating Over & Midsize

318 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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9.21.3 Engine Filter Kits - CAT C13 TIER 3A)


Description QI440 PLANT AND ENGINE FILTER KIT (CAT C13 TIER 3A) - 250HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,


Ballygawley,
Part no. 10-21-9024 Co. Tyrone
N. Ireland
Tel: 028 8556779
Fax: 028 85567007
Ref no. Description Part no. Qty
CAT Engine
1 Engine oil filter EN1000 1
2 CAT Primary Fuel Filter EN1001 1
3 CAT C13 FUEL SECONDARY FILTER EN1006 1

4 PSD 12 MAIN ELEMENT BLUE MEDIA EN9555 1


5 Air filter safety element EN9556 1
Description QI440 PLANT AND ENGINE FILTER KIT (CAT C13 TIER 3A) - 500HRS
Revision 1.00

Modified 13/03/2012 Tullyvannon,


Ballygawley,
Part no. 10-21-9025 Co. Tyrone
N. Ireland
Tel: 028 8556779
Fax: 028 85567007
Ref no. Description Part no. Qty
CAT Engine
1 Engine oil filter EN1000 1
2 CAT Primary Fuel Filter EN1001 1
3 CAT Seconday Fuel Filter EN1006 1

4 PSD 12 MAIN ELEMENT BLUE MEDIA EN9555 1


5 Air filter safety element EN9556 1

PT Tech Clutch
6 Clutch lub filter element HF9920 1
7 Clutch Breather HF9523 1
8 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
9 High pressure filter element 10-21-0321 2
10 Return filter element 10-21-0031 3
11 HYD TANK BREATHER ELEMENT HF9524 1

Fuel Tank
12 HYD TANK BREATHER ELEMENT HF9524 1

320 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Description QI440 PLANT AND ENGINE FILTER KIT (CAT C13 TIER 3A) - 2000HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,


Ballygawley,
Part no. 10-21-9027 Co. Tyrone
N. Ireland
Tel: 028 8556779
Fax: 028 85567007
Ref no. Description Part no. Qty
CAT Engine
1 Engine oil filter EN1000 1
2 CAT Primary Fuel Filter EN1001 1
3 CAT Seconday Fuel Filter EN1006 1

4 PSD 12 MAIN ELEMENT BLUE MEDIA EN9555 1


5 Air filter safety element EN9556 1

PT Tech Clutch
6 Clutch lub filter element HF9920 1
7 Clutch Breather HF9523 1
8 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
9 High pressure filter element 10-21-0321 2
10 Return filter element 10-21-0031 3
11 HYD TANK BREATHER ELEMENT HF9524 1
12 1" SUCTION FILTER 10-21-0003 1
13 2 1/2" SUCTION FILTER 10-21-0007 3

Fuel Tank
14 HYD TANK BREATHER ELEMENT HF9524 1

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9.21.4 Engine Filter Kits - CAT C13 TIER 3B


Description QI440 PLANT AND ENGINE FILTER KIT (CAT C13 TIER 3B) - 500HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,


Ballygawley,
Part no. 10-21-9026 Co. Tyrone
N. Ireland
Tel: 028 8556779
Fax: 028 85567007
Ref no. Description Part no. Qty
CAT Engine
1 Engine oil filter EN1000 1
2 CAT Primary Fuel Filter EN1001 1
3 CAT Seconday Fuel Filter EN1203 2

4 PSD 12 MAIN ELEMENT BLUE MEDIA EN9555 1


5 Air filter safety element EN9556 1

PT Tech Clutch
6 Clutch lub filter element HF9920 1
7 Clutch Breather HF9523 1
8 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
9 High pressure filter element 10-21-0321 2
10 Return filter element 10-21-0031 3
11 HYD TANK BREATHER ELEMENT HF9524 1

Fuel Tank
12 HYD TANK BREATHER ELEMENT HF9524 1

322 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
ID:QI441.en.ver.1
qi441 Spare Parts

Description QI440 PLANT AND ENGINE FILTER KIT (CAT C13 TIER 3B) - 2000HRS
Revision 0.00

Modified 13/03/2012 Tullyvannon,


Ballygawley,
Part no. 10-21-9028 Co. Tyrone
N. Ireland
Tel: 028 8556779
Fax: 028 85567007
Ref no. Description Part no. Qty
CAT Engine
1 Engine oil filter EN1000 1
2 CAT Primary Fuel Filter EN1001 1
3 CAT Seconday Fuel Filter EN1203 2

4 PSD 12 MAIN ELEMENT BLUE MEDIA EN9555 1


5 Air filter safety element EN9556 1

PT Tech Clutch
6 Clutch lub filter element HF9920 1
7 Clutch Breather HF9523 1
8 HYD TANK BREATHER ELEMENT HF9524 1

Hydraulic system
9 High pressure filter element 10-21-0321 2
10 Return filter element 10-21-0031 3
11 HYD TANK BREATHER ELEMENT HF9524 1
12 1" SUCTION FILTER 10-21-0003 1
13 2 1/2" SUCTION FILTER 10-21-0007 3

Fuel Tank
14 HYD TANK BREATHER ELEMENT HF9524 1

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qi441

10.0 Electrical and Hydraulic

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10.1 Electrical Schematics

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qi441 Electrical and Hydraulics

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Gateway/Data Logger
GW3000

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Electrical and Hydraulics qi441

330 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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Gateway/Data Logger
GW3000

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K1

MC88
A102A

A102B
K11
K2
K3
K4

K6 K10
T1

K7 K8 K9 K12 K13

RADIO
7XA
1X1
K14

342 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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LAYOUT OF PANEL LID


1S1
JDP

A101
3S1
2S1
4S1

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X40A
HCP
20A
MAX

X31A

LAYOUT OF PANEL SIDES


X23A
Handset
GX1

X31B
X10A

X47A
X10B

344 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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345
C200 Drive Lamps 1

Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
C201 Drive Lamps 2
C202 Hopper Level

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C210 Side Conveyor Pull Stop
C203 Crusher Speed Sensor
C211 Side Conveyor Speed Sensor
qi441
Electrical and Hydraulics qi441

10.2 Hydraulics

10.2.1 Hydraulic Circuit Diagrams

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qi441

11.0 OEM Section

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11.1 OEM Appendices

Please ensure you read this section carefully. It contains Manuals produced by OEM manufactures,
therefore Sandvik has reservations for misprints. The OEM Manuals will be placed in the following
order

11.1.1 CI421 Impactor Crusher Operation

11.1.2 CI421 Impactor Crusher Maintenance Manual

11.1.3 CI421 Impactor Crusher Spare Parts

11.1.4 CI421 Impactor Crusher Wear Parts

11.1.5 Eriez Magnetic Separator

11.1.6 Roxon Vibrating Feeder

11.1.7 Crawler Tracks Operation Manual

11.1.8 M-PROS Control System Spare Parts

11.1.9 Optional Extra’s

352 Copyright © Sandvik Mining and Construction Mobile Crushers and Screens Ltd.
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